Winco Dr130f4 Setup guide

DR100F4

INSTALLATION AND

OPERATORS MANUAL

DR20I4-DR130F4

GENERATORS

COPY YOUR MODEL AND SERIAL NUMBER HERE

No other WINCO generator has the same serial number as yours.

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 NAME ___________________________________________

DEALER PHONE # ________________________________________

www.wincogen.com

16200-022 16200-025

16200-019 16200-028

16200-013

OPM-109/D

TABLE OF CONTENTS

SAVE THESE INSTRUCTIONS 2

TESTING POLICY 2

SAFETY INFORMATION 3

CALIFORNIA PROPOSITION 65

ANSI SAFETY DEFINITIONS

SPECIFICATIONS 4

DR20I4

DR30I4

DR45F4

DR65F4

DR90F4

DR100F4

DR130F4

INTRODUCTION 8

PRODUCT DESCRIPTION

PREPARING THE UNIT 10

UNPACKING

LIFTING THE GENERATOR SET

INSTALLATION 11

GENERAL INFORMATION

ENGINE GENERATOR SET MOUNTING

INSTALLING THE FUEL LINE

LUBRICATION

INSTALLING THE BATTERY

CONNECTING BATTERY CHARGER & BLOCK HEATER

INSTALLING THE TRANSFER SWITCH

A.C. ELECTRICAL 14

CONNECTIONS 14

GROUNDING

D.C. ELECTRICAL CONNECTIONS 15

DC INTERCONNECTIONS TO THE ATS

STARTING PROCEDURE 16

INITIAL START UP

MAINTENANCE SCHEDULE 18

TROUBLESHOOTING TABLE 19

AVR WIRING 19

WIRING SIZE TABLE 20

ENGINE HARNESS SCHEMATIC 21

DR20

DR45/DR65

DSE 7310 MKII WIRING DIAGRAM 22

THREE PHASE AC WIRING 23

SINGLE PHASE AC WIRING 23

LIMITED WARRANTY 24

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 generator is based on engineering tests

of typical units, and is subject to, and limited by, the

temperature, altitude, fuel, and other conditions specified

by the manufacturer of applicable engines.

This unit comes factory set for either key start or manual

start. With the DSE 7310 MKII controller used in the manual

start option it is possible to wire the control for remote start.

Wiring instructions can be found further in this manual. The

key start version does not have this option.

SAVE THESE INSTRUCTIONS

This manual contains important instructions that should

be followed during installation and maintenance of the

generator. Read and understand all instructions in the

manual before starting and operating the generator.

USING THIS MANUAL

Congratulations on your choice of a WINCO generator.

You have selected a high-quality, precision-engineered

generator designed and tested to give you years of

satisfactory service.

To get the best performance from your new generator, 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.

3OPM-109/D

E. Store fuel only in an approved container, and only in

a well ventilated area.

F. Follow local codes for closeness to combustible

material.

3. DEADLY EXHAUST GAS -

Exhaust fumes from any gasoline engine contain carbon

monoxide, an invisible, odorless and deadly gas that must

be mixed with fresh air.

A. Operate only in well ventilated areas.

B. Never operate indoors including attached garages

C. 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. NOISE HAZARD -

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 periods of time.

B. Keep your neighbors in mind when using this

equipment.

5. CLEANLINESS -

Keep the generator and surrounding 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, including the installation or replacement of

service parts, should be performed 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.

D. Use extreme caution when working on electrical

components. High output voltage from this

equipment can cause serious injury or death.

E. Always avoid hot mufflers, exhaust manifolds, and

engine parts. They can cause severe burns instantly.

F. The use of the engine-generator set must comply

with all

national, state, and local codes.

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

potentially deadly hazards; from electrical shock, exhaust

gas asphyxiation, or fire. Please read all safety instructions

carefully before installation or use. Keep these instructions

handy for future reference. Take special note and follow all

warnings on the unit labels and in the manuals.

CALIFORNIA PROPOSITION 65

WARNING: This product contains crude oil,

gasoline, diesel fuel and other petroleum

products, Antifreeze to which can expose you

to chemicals including toluene and benzene,

Ethylene glycol (ingested) which are known to the

State of California to cause cancer, birth defects or other

reproductive harm and developmental issues.

For more information go to www.P65Warning.ca.gov.

ANSI SAFETY DEFINITIONS

DANGER:

DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

This signal word is to be limited to the most extreme

situations.

WARNING:

WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious injury.

CAUTION:

CAUTION indicates a potentially hazardous situation which,

if not avoided, may result in minor or moderate injury. It

may also be used to alert against unsafe practices.

1. ELECTRICAL SHOCK -

The output voltage present 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 instruction.

B. Guard against electric shock.

C. Avoid contact with live terminals or receptacles.

D. Use extreme care if operating this unit in rain or

snow.

E. Use only three-pronged grounded receptacles

and extension cords.

F. Be sure the unit is properly grounded to an

external ground rod driven into the earth.

2. FIRE HAZARD -

Gasoline and other fuels present a hazard of possible

explosion and/or fire.

A. Do not refuel when the engine is running or hot.

B. Keep fuel containers out of reach of children.

C. Do not smoke or use open flame near the generator

set or fuel tank.

D. Keep a fire extinguisher nearby and know its proper

use. Fire extinguishers rated ABC by NFPA are

appropriate.

OPM-109/D

SPECIFICATIONS

DR20I4

Generator

Wattage 20,000 20,000 20,000 20,000

Volts 120/240 120/208 120/240 277/480

Phase Single Three Three Three

PF 1.0 .80 .80 .80

Amps 83 69 60 30

CB Size 90 75 60 30

Hertz 60 60 60 60

Engine

Model Isuzu 4LE1 2.2L

Starting System 12 Volt

Muffler Standard

Fuel Consumption (full load) 1.8 Gal/Hr

Generator Testing Resistance

Note: Review the Stamford Newage nameplate on your

generator before selecting the correct information below.

Model Stamford PI144D1J

Winding Group 311

Resistances:

Rotor 0.657 Ohms @22°C

Stator 0.377 Ohms Per Ph @ 22°C

Exciter Rotor 0.228 Ohms Per Ph @ 22°C

Exciter Stator 18.5 Ohms @ 22°C

Voltage Regulator AS480

Model Stamford PI1144D

Winding Group 06

Resistances:

Rotor 0.657 Ohms @22°C

Stator 0.377 Ohms Per Ph @ 22°C

Exciter Rotor 0.228 Ohms Per Ph @ 22°C

Exciter Stator 18.5 Ohms @ 22°C

Voltage Regulator AS480

Engine Fluid Specifications

Fuel ASTM D-975 -1D or 2D

EN590 or equivalent

Oil Type SEE LUBRICATION SECTION

Oil Capacity 8.8 Quarts

Cooling System 50/50 mix

DR30I4

Generator

Wattage 29,000 30,000 30,000 30,000

Volts 120/240 120/208 120/240 277/480

Phase Single Three Three Three

PF 1.0 .80 .80 .80

Amps 120 104 90 45

CB Size 125 100 90 45

Hertz 60 60 60 60

Engine

Model Isuzu 4LE1 2.2L

Starting System 12 Volt

Muffler Standard

Fuel Consumption (full load) 3.13 Gal/Hr

Generator Testing Resistance

Note: Review the Stamford Newage nameplate on your

generator before selecting the correct information below.

Model Stamford PI144H

Winding Group 311

Resistances:

Rotor 0.89 Ohms @22°C

Stator 0.179 Ohms Per Ph @ 22°C

Exciter Rotor 0.21 Ohms Per Ph @ 22°C

Exciter Stator 22.9 Ohms @ 22°C

Voltage Regulator AR480

Model Stamford PI1144D

Winding Group 06

Resistances:

Rotor 0.857 Ohms @22°C

Stator 0.073 Ohms Per Ph @ 22°C

Exciter Rotor 0.201 Ohms Per Ph @ 22°C

Exciter Stator 20.3 Ohms @ 22°C

Voltage Regulator AS480

Engine Fluid Specifications

Fuel ASTM D-975 -1D or 2D

EN590 or equivalent

Oil Type SEE LUBRICATION SECTION

Oil Capacity 8.5 Quarts

Cooling System 50/50 mix

5OPM-109/D

DR45F4

Generator

Wattage 45,000 45,000 45,000 45,000

Volts 120/240 120/208 120/240 277/480

Phase Single Three Three Three

PF 1.0 .80 .80 .80

Amps 187 156 135 68

CB Size 175 150 125 70

Hertz 60 60 60 60

Engine

Model FPT N45 SM1 4.5L

Starting System 12 Volt

Muffler Standard

Fuel Consumption (full load) 4.09 Gal/Hr

Generator Testing Resistance

Note: Review the Stamford Newage nameplate on your

generator before selecting the correct information below.

Model Stamford UCI224D

Winding Group 311

Resistances:

Rotor 0.64 Ohms @22°C

Stator 0.065 Ohms Per Ph @ 22°C

Exciter Rotor 0.142 Ohms Per Ph @ 22°C

Exciter Stator 21.0 Ohms @ 22°C

Voltage Regulator SX460

Model Stamford UCI224E

Winding Group 06

Resistances:

Rotor 0.69 Ohms @22°C

Stator 0.02 Ohms Per Ph @ 22°C

Exciter Rotor 0.156 Ohms Per Ph @ 22°C

Exciter Stator 20.0 Ohms @ 22°C

Voltage Regulator SX460

Engine Fluid Specifications

Fuel ASTM D-975 -1D or 2D

EN590 or equivalent

Oil Type SEE LUBRICATION SECTION

Oil Capacity 13.5 Quarts

Cooling System 50/50 mix

DR65F4

Generator

Wattage 62,000 62,000 62,000 62,000

Volts 120/240 120/208 120/240 277/480

Phase Single Three Three Three

PF 1.0 .80 .80 .80

Amps 258 215 186 93

CB Size 250 225 175 100

Hertz 60 60 60 60

Engine

Model FPT N45 SM2 4.5L

Starting System 12 Volt

Muffler Standard

Fuel Consumption (full load) 4.57 Gal/Hr

Generator Testing Resistance

Note: Review the Stamford Newage nameplate on your

generator before selecting the correct information below.

Model Stamford UCI224F

Winding Group 311

Resistances:

Rotor 0.83 Ohms @22°C

Stator 0.033 Ohms Per Ph @ 22°C

Exciter Rotor 0.156 Ohms Per Ph @ 22°C

Exciter Stator 20.0 Ohms @ 22°C

Voltage Regulator SX460

Model Stamford UCI224G

Winding Group 06

Resistances:

Rotor 0.94 Ohms @22°C

Stator 0.1 Ohms Per Ph @ 22°C

Exciter Rotor 0.156 Ohms Per Ph @ 22°C

Exciter Stator 20.0 Ohms @ 22°C

Voltage Regulator SX460

Engine Fluid Specifications

Fuel ASTM D-975 -1D or 2D

EN590 or equivalent

Oil Type SEE LUBRICATION SECTION

Oil Capacity 13.5 Quarts

Cooling System 50/50 mix

OPM-109/D

DR90F4

Generator

Wattage 86,000 90,000 90,000 90,000

Volts 120/240 120/208 120/240 277/480

Phase Single Three Three Three

PF 1.0 .80 .80 .80

Amps 358 312 271 135

CB Size 350 300 250 125

Hertz 60 60 60 60

Engine

Model FPT N45 TM2 4.5L

Starting System 12 Volt

Muffler Standard

Fuel Consumption (full load) 6.94 Gal/Hr

Generator Testing Resistance

Note: Review the Stamford Newage nameplate on your

generator before selecting the correct information below.

Model Stamford UCI274C

Winding Group 311

Resistances:

Rotor 1.19 Ohms @22°C

Stator 0.0045 Ohms Per Ph @ 22°C

Exciter Rotor 0.136 Ohms Per Ph @ 22°C

Exciter Stator 18.0 Ohms @ 22°C

Voltage Regulator SX460

Model Stamford UCI274C

Winding Group 06

Resistances:

Rotor 1.37 Ohms @22°C

Stator 0.0037 Ohms Per Ph @ 22°C

Exciter Rotor 0.136 Ohms Per Ph @ 22°C

Exciter Stator 18.0 Ohms @ 22°C

Voltage Regulator SX460

Engine Fluid Specifications

Fuel ASTM D-975 -1D or 2D

EN590 or equivalent

Oil Type SEE LUBRICATION SECTION

Oil Capacity 13.5 Quarts

Cooling System 50/50 mix

DR100F4

Generator

Wattage 100,000 105,000 105,000 115,000

Volts 120/240 120/208 120/240 277/480

Phase Single Three Three Three

PF 1.0 .80 .80 .80

Amps 416 364 315 172

CB Size 400 350 300 175

Hertz 60 60 60 60

Engine

Model FPT N67 TM1 6.7L

Starting System 12 Volt

Muffler Standard

Fuel Consumption (full load) 7.71 Gal/Hr

Generator Testing Resistance

Note: Review the Stamford Newage nameplate on your

generator before selecting the correct information below.

Model Stamford UCI274D

Winding Group 311

Resistances:

Rotor 1.19 Ohms @22°C

Stator 0.0045 Ohms Per Ph @ 22°C

Exciter Rotor 0.136 Ohms Per Ph @ 22°C

Exciter Stator 18.0 Ohms @ 22°C

Voltage Regulator SX460

Model Stamford UCI274D

Winding Group 06

Resistances:

Rotor 1.37 Ohms @22°C

Stator 0.0037 Ohms Per Ph @ 22°C

Exciter Rotor 0.136 Ohms Per Ph @ 22°C

Exciter Stator 18.0 Ohms @ 22°C

Voltage Regulator SX460

Engine Fluid Specifications

Fuel ASTM D-975 -1D or 2D

EN590 or equivalent

Oil Type SEE LUBRICATION SECTION

Oil Capacity 18 Quarts

Cooling System 50/50 mix

7OPM-109/D

DR130F4

Generator

Wattage 123,000 130,000 130,000 130,000

Volts 120/240 120/208 120/240 277/480

Phase Single Three Three Three

PF 1.0 .80 .80 .80

Amps 512 451 391 195

CB Size 500 450 400 200

Hertz 60 60 60 60

Engine

Model FPT N67 TM1 6.7L

Starting System 12 Volt

Muffler Standard

Fuel Consumption (full load) 8.8 Gal/Hr

Generator Testing Resistance

Note: Review the Stamford Newage nameplate on your

generator before selecting the correct information below.

Model Stamford UCI274F

Winding Group 311

Resistances:

Rotor 1.19 Ohms @22°C

Stator 0.0045 Ohms Per Ph @ 22°C

Exciter Rotor 0.136 Ohms Per Ph @ 22°C

Exciter Stator 18.0 Ohms @ 22°C

Voltage Regulator SX460

Model Stamford UCI274F

Winding Group 06

Resistances:

Rotor 1.37 Ohms @22°C

Stator 0.0037 Ohms Per Ph @ 22°C

Exciter Rotor 0.136 Ohms Per Ph @ 22°C

Exciter Stator 18.0 Ohms @ 22°C

Voltage Regulator SX460

Engine Fluid Specifications

Fuel ASTM D-975 -1D or 2D

EN590 or equivalent

Oil Type SEE LUBRICATION SECTION

Oil Capacity 18 Quarts

Cooling System 50/50 mix

OPM-109/D

ENGINE

Refer to the engine operators manual for more detailed

operation and maintenance information.

CAUTION: EQUIPMENT DAMAGE:

Be sure to check the engine oil level frequently as specified

in the engine manual.

The engine manufacturer has established an excellent

worldwide engine service organization; engine service is

available from a nearby authorized dealer or distributor. Go

to the WINCO website for a list of engine dealers (http://

wincogen.com/Engine_Support) or contact the WINCO

Service Department.

The rated power of each engine-generator is limited by

the temperature, altitude, and all other ambient conditions

specified by the engine manufacturer. Engine power may

decrease 3½% for each 1000 feet above sea level, and will

decrease an additional 1% for each 10 degrees Fahrenheit

above 60° Fahrenheit. Units should not be operated in

ambient temperature greater than 125° Fahrenheit.

GENERATOR

WINCO generator sets use brushless, AVR (Auto-Voltage

Regulator) controlled broad-range generator ends. The

generator converts rotational mechanical energy into

electrical energy. These WINCO units are equipped

with generators manufactured by Cummins Generator

Technology. Each generator ‘end’ has its own data tag. A

unique serial number is on the data plate.

MODEL NUMBER STRUCTURE

The WINPOWER alpha-numerical numbering consists

of a base model designation, followed by an options

section, separated by a dash mark. The base component

of the model numbering system identifies an engine type,

engine starting method, fuel type, kilowatt rating, engine

manufacturer, and number of generator poles. Following

the separation dash mark is the voltage connection and

optional installed equipment. Options include features like,

weather enclosures (housing), base mounted fuel tank

sizes, and trailer options.

Please note that some features or packages, such as

NFPA level I & II, do not have an indication place in this

numbering system. They are issued and built with an

M-Spec (i.e. M-10372) number which can be found on

the WINPOWER data tag. When the M-Spec is present,

supplemental inserts will accompany this standard manual

providing information about the special equipment and

features installed. The standard model numbering key that

can be used along with the data tag information and/

or M-Spec supplements to determine the generator set’s

ratings and specifications.

INTRODUCTION

PRODUCT DESCRIPTION

This engine-generator set is designed for unattended

remote start operation. It can be operated as part of a

fully automatic standby power system or independently

as a local start unit in a prime power system. The engine-

generator set is fully tested at the factory prior to shipment

to insure proper operation of each individual component as

well as the total system’s performance and reliability.

The engine generator set consists of a multi-cylinder, liquid

cooled engine nominally operating at 1800 rpm. The

generator frequency regulation is maintained by the engine

governor to within +/- 1.5 Hz (cps), from no load to rated

load for standard mechanical governors and to within +/- .5

Hz or better for units equipped with an electronic governor.

The generator is a single bearing, direct drive, rotating field

design. The generator is connected to the engine flywheel

via flexible drive disks. Generator set is skid mounted with

isolation mounts between the engine and base on all units.

A customer supplied 12 Volt battery is required to complete

the installation. Battery requirements are listed later under

the battery installation section.

Unit Orientation Note: All references used in this manual

for unit familiarization, access and component locations on

the Generator Set are oriented from a TOP (plan) VIEW with

engine at the FRONT and generator to the REAR.

WINPOWER uses a common junction box for all customer

control and power connections (both AC output and DC

control). The common electrical junction box is always on

the left side at the generator end of the machine.

The engine is controlled and Generator Set operation

is monitored for safe operation by a programmable

microprocessor based electronic Engine Control Module

(ECM) with an LCD digital display. The generator set ECM

control is mounted on a vertical pedestal on the right side

of the generator. The ECM is programmed with a cycle

cranking sequence - 3 cycles of 15 seconds on/15 seconds

off, and 5 minute cool-down delay. The cool-down delay

can be changed in the field from 0 to 30 minutes by your

installer. Other features, timing cycles, set points, and

signal output capabilities are possible. Consult factory for

procedure and passwords.

NOTICE:

These units will automatically transfer if a power outage

occurs while running in exercise mode.

GENERATOR SET

Every WINCO generator set has its own unique identity

data plate. This data plate identifies the complete unit

model number, the system serial number, and has links to

the individual components that form the generator set in

our factory records. Several of the major components also

have their own individual data plates providing additional

information to document build data for warranty and

replacement parts.

9OPM-109/D

DD = Diesel

RR = Remote Start

30 Generator Output Rating in kW

IEngine Manufacturer: I = Isuzu; F = FPT

4Number of Generator Poles

-Base Unit - Options Separator

Voltage

A (3) = Single Phase 120/240V

D (4) = Three Phase 120/208V

J (17) = Three Phase 120/240V

L (18) = Three Phase 277/480V

HOUSING TYPE

A = Sound Attenuated/Weather Protective

* = No Housing

MFuel Tank Size: S = Small; M = Medium; L = Large;

P = Plastic; * = None

TT = Trailer; * = None

Battery Charger Options

A = 12V/.75A; B = 12V/3.5A; C = 12V/6A; D = 12V/10A;

E = 12V/6A NFPA; F = 12V/10A NFPA; G = 24V/3.5A;

H = 24V/10A; I = 24V/10A NFPA; J = 12V/2A;

K = 12VDC/5A DSE; L = 24VDC/10A DSE

OPM-109/D

PREPARING THE UNIT

UNPACKING

1. As you receive your unit, it is critical to check it for any

damage. If any damage is noted, it is always easiest to

refuse the shipment and let WINCO take care of the freight

claim. If you sign for the unit, the transfer of the ownership

requires that you file the freight claim

2. Before proceeding with the preparations of your new

generator for operation, take a couple of minutes to ensure

the unit you have received is the correct model and review

the specification pages in this manual to ensure that this

unit meets your job requirements.

CAUTION: EQUIPMENT DAMAGE:

This unit is shipped with oil and a 50/50 mix of coolant. Be

sure to check all fluid levels before operating. See engine

manufacturer’s instruction manual for recommended oil

requirements before initial starting.

Once generator set is on-site:

1. Carefully remove the crate.

2. After inspecting the engine-generator for external,

physical damage, locate and check the following items

packed with the unit:

a. Installation and Operator’s Manual.

b. Engine manufacturer’s instruction manual.

c. Battery hold-down brackets & hardware.

d. Unit components or accessory items shipped loose

for on-site installation.

e. Optional accessories.

3. Remove main frame hold-down bolts.

4. Unit can now be lifted from shipping rails.

LIFTING THE GENERATOR SET

NOTICE: PERSONAL INJURY:

To prevent injury to persons or equipment, observe the

following guidelines when lifting the generator:

Due to the different designs, configurations, options,

weights, site conditions, and available material handling

equipment, specific lifting instructions are not provided for

each individual generator set model. General guidelines

provided are applicable to the entire generator line. It

is the responsibility of the installing party to follow the

lifting equipment’s operator’s manual to prevent injury to

personnel and damage to the generator. Smaller generator

sets may not require use of overhead lifting equipment and

may be placed on the pad with basic material handling

equipment, i.e. a forklift.

CAUTION:

Do not attempt to lift the generator set by the means of

the lifting eyes on the engine or generator end. These

lifting points are only for the use during the manufacturing

process and are designed for lifting of the individual

generator set components.

WARNING:

NEVER attempt to lift the fuel tank filled with fuel. Sloshing

of the fuel can cause a shift in the balance of the fuel tank,

making for a DANGEROUS, unbalanced lifting load. If the

generator was shipped on the fuel tank, use the lifting

points located on the fuel tank to move the entire generator

set into place. DO NOT PLACE FUEL IN THE TANK PRIOR

TO LIFTING.

11 OPM-109/D

INSTALLATION

WARNING: PERSONAL INJURY:

PERSONAL INJURY - Before proceeding with the

installation, be sure the DSE 7310 MKII is in the “stop”

position. Before proceeding with the installation, be sure

the Generator MLCB (Main Line Circuit Breaker) is in the

‘OFF’ position and the unit starting battery is disconnected.

GENERAL INFORMATION

This engine-generator set is generally supplied as weather

enclosed packages for quick installation on an outdoor

concrete pad. They are also available as open skid mounted

units for indoor installation in a building or protective

enclosure, properly ventilated, supplied by the installer. The

factory weather enclosures are acoustical housing intended

for outdoor installation only. Factory weather enclosed

units are not intended to be used indoors and no support is

available to assist in re-engineering finished packaged units.

All versions must be bolted to a solid base for proper

operation. A properly designed concrete pad is necessary

for stationary operation. A substantial DOT certified trailer

is required for mobile applications. Consult a qualified,

licensed electrician or contractor to install and wire the gen-

set. The installation must comply with all national, state, and

local codes.

Before beginning the installation process, recheck the

voltage, phase, and amperage rating of the generator

set. Be certain it can handle the intended load and are

compatible with the intended loads. Plans for installation

should be prepared with proper attention to mechanical

and electrical engineering detail to assure a satisfactory

system installation.

The information in this manual is offered only as a guide to

finalizing your installation plans.

Notice:

For full service switching of the entire load, the ATS must be

‘SE’ (Service Entrance) rated or must have a properly rated

fusible disconnect installed before the ATS to protect the

contacts.

ENGINE GENERATOR SET MOUNTING

The unit’s main frame must be bolted solidly to a solid base.

The engine-generator is mounted on channels which are

attached with special shock mounts to the main frame.

This allows the engine-generator free movement without

affecting the base or surrounding equipment.

WARNING: EQUIPMENT DAMAGE:

Never mount these engine-generator sets to a wooden

base/structure. Over time, the wood will deteriorate and

the unit mountings will come loose. These units must be

mounted to a steel or concrete base.

The unit should be mounted to allow ample working room

around it. A general rule to follow is to allow 24 inches or

more of clearance for maintenance. Follow local codes for

clearance from combustible surfaces.

INSTALLING THE FUEL LINE

WARNING: FIRE DANGER:

Connecting rigid fuel line (i.e. steel or copper line) directly

to the inlet fuel filter or fuel pump may cause the fuel line to

crack during operation creating a serious fire hazard.

The fuel supply should be as close to the engine as

possible. This will reduce the installation cost of fuel runs

and minimize line losses. The diesel fuel supply should be

no more than 3 feet below the fuel inlet on the pump. If

your fuel supply is lower than three feet you may have to

install an additional lift pump to bring the fuel up to the

mechanical fuel pump on the engine.

The information in this manual is offered to assist you in

providing the proper fuel for your engine. However, this

information is only provided to inform you of the engine’s

requirements and assist in making you aware of the

decisions you must make. In no case should the instructions

or information provided be interpreted to conflict with any

local, state, or national codes. If in doubt, always consult

your local fire marshal or fuel supplier.

Engine generator sets are properly adjusted before they

leave the factory. Connecting a fuel supply with adequate

supply volume is critical to reliable operation. Diesel units

with optional base mounted fuel tanks are pre-plumbed to

the mechanical fuel pump on the engine.

Open skid mounted Diesel units are often supplied with

capped inlet and return lines. The use of a sustainable

customer supplied flexible fuel line is essential between

the engine and fuel supply to provide a vibration break

between your fuel supply and the engine.

LUBRICATION

Before starting the engine, check the oil level in the

crankcase. If it is low, refill to the full mark with the proper

weight/grade of oil as recommended by the engine

manufacturer’s maintenance instructions. The necessity of

using the correct oil, and keeping the crankcase full, cannot

be over emphasized. Failure to use the proper oil and keep

the crankcase properly filled will cause excessive engine

wear and shorten its useful life.

WINCO recommends our 5W-30 for Isuzu engines and

5W-40 for FPT engines, fully synthetic heavy duty engine

oil to give you maximum cold weather protection while

maintaining excellent performance in warmer weather. We

have partnered with a national lubrication oil manufacturer

to give you access to Winco private branded premium oil

available at comparable prices to conventional oils. See your

dealer for additional information.

DR20I4 & DR30I4

OPM-109/D

DR45F4 - DR130F4

INSTALLING THE BATTERY

CAUTION:

In the following battery installation procedure, check to be

sure the DSE 7310 MKII is in the “stop” position. This should

be your last step before initial start-up.

A customer supplied Group 24/350 CCA battery is required

to complete the installation. Installation of the highest CCA

rated battery, within the correct BCI group, will increase

cold weather starting performance.

BATTERY REQUIREMENTS

Model Voltage BCI

Group

Min. CCA

Rating

DR20I4 - DR65F4 12 24 650

DR90F4 - DR130F4 12 31 900

Installation and servicing of batteries must only be

preformed or supervised by personnel knowledgeable of

batteries and the required precautions. Keep unauthorized

personnel away from batteries.

When installing or replacing batteries, use the proper

group/size starting battery. The battery should be a

maintenance-free lead acid design. Deep cycle batteries will

not work for this application.

CAUTION: PERSONAL DANGER:

NEVER dispose a battery in a fire. The battery is capable of

exploding.

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 battery

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 battery, reverse the

procedure, disconnect the negative first and 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 diluted sulfuric acid that is harmful to the

skin and eyes. It is electrically conductive and corrosive. The

following precautions must always be taken.

1. Always wear full eye protection and protective

clothing.

2. Where electrolyte contacts skin, wash off immediately

with water.

3. If electrolyte contacts the eyes, flush thoroughly and

immediately with water and seek immediate medical

attention

4. 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:

1. Never smoke when near batteries.

2. Do not cause a flame or spark in the battery area.

3. Always discharge static electricity from your body

before touching batteries by first touching a ground

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. Different types of batteries

require various types of maintenance. Refer to the battery

manufacturer for specific recommendations.

NOTE: Always make sure that a new battery is fully charged

before installing it on a generator set. Failure to do so

can cause damage to the engine control module in the

generator set.

All connections must be clean and tight. Depending on

your battery type, check the electrolyte in the battery

periodically to be sure it is above the plates. Never allow the

battery to remain in a discharged condition.

13 OPM-109/D

CONNECTING BATTERY CHARGER &

BLOCK HEATER

A three-stage battery charger is provided standard on

this unit. The charger is an Automatic Battery Charger &

Maintainer. This charger has three rates of charging. During

the first mode, known as Bulk charging, the charging

current is limited to 10 Amps at a voltage of up to 14 Volts.

The yellow LED will be on constantly during this stage.

When the charging rate drops to 2.5 Amps, the charge will

enter the ABSORPTION charging mode. During this mode,

the yellow LED will be flashing. The charging voltage is

held at 14 Volts and the charging rate gradually reduces

the amount of current (Amps) flowing to the battery to

100% charged state. The battery can be left on this mode

indefinitely. During this mode, the green LED will be on

constantly.

This charger is mounted under the customer connection

on the control side of the generator and plugged into the

receptacle mounted in the AC connection cabinet. The

battery charger receptacle is to be powered by a GFCI

circuit and installed in accordance to the US National

Electric Code. It is suggested that this circuit be fused to 20

Amps.

The block heater on this unit is a 750 watt heater can

use the same 20 Amp GFCI fused circuit. This circuit will

terminate on the 120 Volt terminal block mount in the

customer connection cabinet. The engine blockheater

installed on this unit should also be plugged into this

receptacle. The block heater is thermostatically controlled

when plugged in will maintain the engine coolant

temperature between 100 and 120 degrees F.

INSTALLING THE TRANSFER SWITCH

WARNING: FIRE HAZARD:

All wiring must be done by a licensed electrician, and must

conform to the National Electrical Code and comply with

all the local codes and regulations. Check with the local

authorities before proceeding.

INSTALLATION NOTES:

Because of many different types of service, feeder and

distribution equipment, no specific wiring instructions

can be provided. It is recommended that only copper

wire be used. In all cases it is essential that while the load

is connected to the generator, there can be absolutely

no feedback from the generator to the power line or the

power line to the generator. When properly installed, the

normal ATS Control and safety system will eliminate all

paths and feedback.

To wire the automatic transfer switch into existing wiring,

first determine which circuits will be on the emergency load

circuit. If the entire load is transferred, the transfer switch

can be wired directly after the watt-hour meter and the

service entrance, providing the service entrance ampere

rating is within the transfer switch’s rated capability.

If only specific circuits are to be powered under emergency

power failure conditions, an additional distribution panel

designated “emergency distribution panel” must be

installed.

All selected emergency circuits are removed from main

distribution panels and installed in the emergency

distribution panel. The ATS is then installed between

the main panel and the emergency distribution panel.

Suggested circuits: freezer, refrigerator, furnace, emergency

lights, sump pump, emergency outlet circuits, etc. Total

running load must not exceed generator rating.

OPM-109/D

generator power feeds have already been wired into the

upper lugs.

Please refer to the circuit breaker installed on your unit for

breaker lug capacities and proper toque specifications.

To select the proper conductor size between the generator

and the ATS, first look your model up in Table 1 of Appendix

“A” for your generator amperage, found further in this

manual. Then refer to Appendix “2” for guidance on wire

sizing based on both wire type and amperage.

For additional information on wire sizes, refer to table 310-

16 of the National Electrical Code ANSI/NFPA 70.

C. GROUND LUG:

These ground lugs are bonded to ground and are provided

for you to connect your ground wire from the transfer

switch to. The lugs will accommodate #10 AWG to 2/0

AWG and should be torqued to 200 in. lbs.

D: 120V GFCI CIRCUIT TERMINAL BLOCK:

These terminals are rated for 85 Amps and will handle wire

sizes #4 AWG to 18AWG. They should be torqued to 16

in. lbs. This circuit must be fed from a fused circuit in the

distribution panel and provides power for the blockheater

and the battery charger.

E: 120V/20 AMP DUPLEX RECEPTACLE:

This convenience receptacle is used to power both battery

charge and blockheater. This circuit must be fed from a

GFCI fused circuit in the distribution panel.

F: NEUTRAL TO GROUND LEAD LUG:

This lug is provided on the neutral terminal block to allow

you to run a neutral to ground lead if you are using the

generator in a stand alone application. This would be an

application where there is not a distribution panel and

no other ground to neutral bond in the wiring system. If

a grounding wire is attached here, remove the floating

neutral label in the panel. This will not be used when you

are wiring a generator and transfer switch into an existing

power system.

WARNING:

A mainline circuit breaker has been provided inside the

generator housing. During all wiring installations, make

sure the breaker is in the OFF position and the generator

operating switch is in the OFF position.

WARNING: EQUIPMENT DAMAGE:

When installing a three-phase 240 Volt system, be sure you

know which lead is the high voltage “wild” leg (208 Volt

line to neutral). The generator normally carries the high

voltage on the G2 lead.

All wires should be installed in rigid or flexible conduit

(knockouts are provided in the control box).

GROUNDING

A grounding lug has been provided on the engine

generator set and the generator set must be properly

grounded to good earth ground. Generally an 8 foot

copper rod driven into the earth will provide a proper earth

ground.

A.C. ELECTRICAL

CONNECTIONS

NOTICE: CLASS 1 WIRING METHODS ARE TO BE USED FOR

ALL FIELD WIRING CONNECTIONS TO TERMINALS OF A

CLASS 2 CIRCUIT

All wiring must be completed in accordance with the

National Electric Code as well as any state and local codes.

You must pay particular attention to wire size requirement

for the amperage of service you are dealing with. The table

below provides you guidance on wire sizing based on both

wire type and amperage. Wire amperages have been

derated for 40° C ambient temperatures operation.

WARNING:

Make sure the generator is disconnected from the battery to

prevent accidental starting.

Typical arrangements for 20kW to 45kW Circuit Breaker Box.

Typical arrangements for 65kW to 135kW Circuit Breaker Box.

A. NEUTRAL LUGS:

These lugs are isolated from ground and provided for you

to connect your neutral wire from the transfer switch to the

generator.

The 1000 Amp terminal block lugs on the 130kW will

handle wire sizes #3/0 to 500 MCM and should be torqued

to 28 ft. lbs. (Rated for 900 for AL)

The 400 Amp terminal block lugs on the 65 & 95kW will

handle wire sizes #1 AWG to 400 MCM and should be

torqued to 300 in. lbs.

The 225 Amp terminal block lugs on the 20 to 45kW will

handle wire sizes #4 to 300 MCM and should be torqued to

250 in. lbs.

B. GENERATOR CIRCUIT BREAKER:

This circuit breaker provides overload protection for the

generator. Your power feeds from the transfer switch

will connect the bottom lugs on the circuit breaker. The

15 OPM-109/D

D.C. ELECTRICAL CONNEC-

TIONS

All DC connections are completed on the terminal strip

just below the engine control. All DC connection must be

separate conduit. You cannot mix AC and DC leads at the

same conduit.

To install the wires, reference the following picture. Use a

small flat head screwdriver to push the release spring inside

the square hole (A). While the release is being pushed,

insert the wire into the larger circular hole (B). Remove the

screwdriver to secure the wire into place.

CONNECTION BOX TERMINALS

Wire size requirements for each of the connections may

vary but terminal lugs should be used for all connections.

Torque spec for terminal lugs is 9 in. lbs.

A - Customer Remote Start CONNECTIONS TERMINALS. The

two remote start leads from the Automatic Transfer Switch

are connected to the two terminals marked Remote Start

& Remote Start. The wire in terminal labeled #1 is Battery

Negative/Ground and the wire in the terminal labeled #23

is your Remote Start lead. Closing these two leads together

will signal the DSE 7310 MKII to go into an autostart mode

and start up the engine generator.

Depending on the distance, 14 to 16 gauge stranded wire

should be used. It is suggested that these wires be labeled

S1 and S23.

Note: Any relay closure can be used to start and stop this

generator. As long as the contact stays closed the engine

generator set will continue to run. Once the relay is opened

the unit will shut down and remain in the standby mode

until the remote start relay is closed again.

B - ESTOP- & ESTOP+. Remote Emergency Stop terminals.

These two terminals are shipped with a jumper installed.

If your application requires the installation of a Remote

Emergency Stop switch, remove the jumper and wire your

switch to these terminals. This unit will not start and run

without either the jumper installed or a remote N/C switch

installed..

C - Battery Charger Failure. Battery charger failure relay

input from remote battery charger to DSE7310 controller.

D - Remote Display Panel Interface Terminals. These

interface terminals are pre-wired to allow for the connection

of a remote display. This display allows for the remote

annunciation of alarms at a location such as a nurses station

or a control room.

E - Battery Positive and Ground ( battery negative). These

terminals are dedicated for any accessory that will be

installed. There is a maximum of 7 Amps combined.

DC INTERCONNECTIONS TO THE ATS

WARNING:

Be sure Engine/Generator is in the OFF position before you

make any DC interconnections.

CAUTION:

Never run the AC and DC wiring in the same conduit.

ASCO 185 UL SWITCH

ASCO 300 UL SWITCH

Your DC connection points

in the ASCO 300 ATS

terminals “14” and “15”.

Depending on the size of

the switch, they are located

in different locations.

135060-00 60708-165

A - Customer Remote Start CONNECTIONS TERMINALS. The

two remote start leads from the Automatic Transfer Switch are

connected to the two terminals marked GROUND & START. The

wire in terminal GROUND is Battery Negative and the wire in the

terminal labeled START is your Remote Start lead. Closing these

two leads together will signal the DSE 7310 to go into an auto-

start mode and start up the engine generator.

Depending on the distance, 14 to 16 gauge stranded wire

should be used. It is suggested that these wires be labeled S1

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B - ESTOP- & ESTOP+. Remote Emergency Stop terminals.

These two terminals are shipped with a jumper installed. If your

application requires the installation of a Remote Emergency

Stop switch, remove the jumper and wire your switch to these

terminals. This unit will not start and run without either the

jumper installed or a remote N/C switch installed..

C. - Battery Charger Failure. Battery charger failure relay input

from remote battery charger to DSE7310 controller.

D - Remote Display Panel Interface Terminals. These

interface terminals are prewired to allow for the connection of a

remote display. This display allows for the remote annunciation

of alarms at a location such as a nurses station or a control

room. This display can used to meet the remote annunciation

requirements of NFPA 110 standards. (This feature meets the

annunciation requirements in applications requiring NFPA110

level one protection.)

DC Interconnections to the

Automatic Transfer Switch

*************

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ASCO 300 UL SWITCH

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located in different locations.

TB7

removable

terminal block

TB7–4, TB7–5, TB7–6

123456789

Figure 4. TB7 generator starting contact terminals.

Table A. Generator Start Connections

When the Utility fails Terminals on Controller

contact closes TB7–4 and TB7–5

contact opens TB7–5 and TB7–6

TB7 Generator starting contact terminals

135060-00 60708-165

A - Customer Remote Start CONNECTIONS TERMINALS. The

two remote start leads from the Automatic Transfer Switch are

connected to the two terminals marked GROUND & START. The

wire in terminal GROUND is Battery Negative and the wire in the

terminal labeled START is your Remote Start lead. Closing these

two leads together will signal the DSE 7310 to go into an auto-

start mode and start up the engine generator.

Depending on the distance, 14 to 16 gauge stranded wire

should be used. It is suggested that these wires be labeled S1

JURXQGDQG6VWDUW The terminal blocks are designed to

use terminal lugs on all wires and the screws should be torqued

to 9.6 in. lbs.

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B - ESTOP- & ESTOP+. Remote Emergency Stop terminals.

These two terminals are shipped with a jumper installed. If your

application requires the installation of a Remote Emergency

Stop switch, remove the jumper and wire your switch to these

terminals. This unit will not start and run without either the

jumper installed or a remote N/C switch installed..

C. - Battery Charger Failure. Battery charger failure relay input

from remote battery charger to DSE7310 controller.

D - Remote Display Panel Interface Terminals. These

interface terminals are prewired to allow for the connection of a

remote display. This display allows for the remote annunciation

of alarms at a location such as a nurses station or a control

room. This display can used to meet the remote annunciation

requirements of NFPA 110 standards. (This feature meets the

annunciation requirements in applications requiring NFPA110

level one protection.)

DC Interconnections to the

Automatic Transfer Switch

*************

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*************

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ASCO 300 UL SWITCH

Your DC connection points in the ASCO 300 ATS are terminals

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located in different locations.

TB7

removable

terminal block

TB7–4, TB7–5, TB7–6

123456789

Figure 4. TB7 generator starting contact terminals.

Table A. Generator Start Connections

When the Utility fails Terminals on Controller

contact closes TB7–4 and TB7–5

contact opens TB7–5 and TB7–6

135060-00 60708-165

A - Customer Remote Start CONNECTIONS TERMINALS. The

two remote start leads from the Automatic Transfer Switch are

connected to the two terminals marked GROUND & START. The

wire in terminal GROUND is Battery Negative and the wire in the

terminal labeled START is your Remote Start lead. Closing these

two leads together will signal the DSE 7310 to go into an auto-

start mode and start up the engine generator.

Depending on the distance, 14 to 16 gauge stranded wire

should be used. It is suggested that these wires be labeled S1

JURXQGDQG6VWDUW The terminal blocks are designed to

use terminal lugs on all wires and the screws should be torqued

to 9.6 in. lbs.

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B - ESTOP- & ESTOP+. Remote Emergency Stop terminals.

These two terminals are shipped with a jumper installed. If your

application requires the installation of a Remote Emergency

Stop switch, remove the jumper and wire your switch to these

terminals. This unit will not start and run without either the

jumper installed or a remote N/C switch installed..

C. - Battery Charger Failure. Battery charger failure relay input

from remote battery charger to DSE7310 controller.

D - Remote Display Panel Interface Terminals. These

interface terminals are prewired to allow for the connection of a

remote display. This display allows for the remote annunciation

of alarms at a location such as a nurses station or a control

room. This display can used to meet the remote annunciation

requirements of NFPA 110 standards. (This feature meets the

annunciation requirements in applications requiring NFPA110

level one protection.)

DC Interconnections to the

Automatic Transfer Switch

*************

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*************

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ASCO 300 UL SWITCH

Your DC connection points in the ASCO 300 ATS are terminals

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located in different locations.

TB7

removable

terminal block

TB7–4, TB7–5, TB7–6

123456789

Figure 4. TB7 generator starting contact terminals.

Table A. Generator Start Connections

When the Utility fails Terminals on Controller

contact closes TB7–4 and TB7–5

contact opens TB7–5 and TB7–6

OPM-109/D

INITIAL START UP

WARNING: EQUIPMENT DAMAGE:

Before attempting to start this unit, complete your pre-start

checklist and ensure the generator mainline circuit breaker

is in the proper position prior to starting. Starting this unit

without it properly connected can cause serious personal

injury or equipment damage.

DO NOT jump start these engine-generator sets. Starting

these units on a low battery or jump starting them will

cause damage to the engine control module.

Use the following check list to verify correct installation

before starting the engine.

□Engine oil. Fill as required with proper grade/qty.

□Engine coolant. Fill as required with proper mixture.

□Unit mounting base properly bolted down.

□Clearance for service and maintenance on all sides.

□Proper fuel line material and size.

□All fuel line connections tight.

□Battery connections clean and tight

□Battery fully charged.

□All AC and DC wiring installed and properly protected.

□Compressor oil. Fill as required with proper grade/qty.

After completing the previous checklist, the engine-

generator set is ready for initial start-up.

MANUAL MODE

1. Press and release the Manual Mode button. The small

LED light

next to it should come on.

Note: There is no start delay in this mode of operation.

2. Press and release the green Start Engine button. The

DSE 7310 MKII will send two signals to the engine. The first

signal wire #21 will engage the fuel solenoid, the second

wire, #22, will engage the starter on the engine. At this

point the DSE 7310 MKII will start the cranking cycle (10

seconds on and 10 seconds off).

Note: Wire #93 is energized to turn on the glow plugs for

15 seconds first and then the starter and fuel solenoid are

engaged.

If the engine fails to start during this cranking period, the

starter motor is disengaged and goes into a rest mode after

which a second attempt is made to start the engine. Should

this sequence continue through 3 cranking cycles the start

sequence will be stopped and the display will show ‘FAILED

TO START”.

3. During manual operation, the load will not normally be

applied to the generator. But caution must be used, if the

line power should fail or be turned off the transfer switch

during manual operation the load may be applied to the

generator.

With the engine running smoothly check the no load

voltage and frequency on the digital display. The voltage

should be 208/240/480 AC depending on which model

you have and a frequency of 59.5 to 60.5 hertz (Hz).

STARTING PROCEDURE

CONTROL LAYOUT

STOP/RESET - This button places the module into its Stop/

Reset mode. This will clear any alarm conditions for which

the triggering criteria have been removed. The fuel supply

de-energizes and the engine comes to a standstill. Should a

remote start signal be present while operating in this mode,

a remote start WILL NOT occur.

MANUAL MODE - This button places the module into its

Manual Mode. Once in Manual Mode, the model responds

to the Start button to start the generator and run it off load.

START - Pressing this button from STOP/RESET will start the

engine and run the load.

AUTO MODE - This button places the module into its Auto

Mode. This mode allows the module to control the function

of the generator automatically.

ALARM/LAMP TEST - This button silences the audible alarm

in the controller, de-activates the Audible Alarm output (if

configured) and illuminates all of the LEDs on the module’s

face as a lamp test function.

MENU NAVIGATION - Used for navigating the

instrumentation, event log, and configuration screens.

PROTECTIONS

When an alarm is present, the common alarm LED if congures will

illuminate. The LCD display will show an icon to indicate the failure.

WARNINGS

Warnings are non-critical alarm conditions and do not affect the

operation of the generator system, they serve to draw the operator’s

attention to an undesirable condition. Warning alarms are self-resetting

when the fault condition is removed. The icon will appear steady in the

display.

SHUTDOWN

Shutdowns are critical alarm conditions that stop the engine and draw

the operator’s attention to an undesirable condition. Shutdown alarms

are latching. The fault must be removed and the STOP/RESET button

pressed to reset the module. The icon will be ashing in the display.

17 OPM-109/D

If you have the proper voltage at the generator the next

step is to check the voltage at the generator terminals in

the Automatic Transfer Switch. The voltage between the

G1 and the G3 terminals should be the same as it was

on the generator front panel. The voltage should also be

checked between the hot terminals (G1 and G3) and the

G-N to be certain of a balanced voltage output and a solid

neutral connection. The voltage between G1 and G-N

should be about 120 volts AC (277 on 480 units). The same

approximate voltage should be found between terminals

G3 and G-N (120 volts AC).

On three phase panels the G2 voltage level should also be

checked. ON 240 VOLT (DELTA) SYSTEMS BE SURE YOU

KNOW WHERE THE HIGH VOLTAGE “WILD” LEG IS. IT

MUST BE IN THE SAME LOCATION ON THE LINE SIDE AS IT

IS ON THE GENERATOR SIDE.

(i.e. if it’s on L-3 on the line side it must be on G-3 on the

generator side. Also on three phase systems make sure that

the rotation is the same on the generator as it is on your

line power. Failure to insure proper rotation will cause three

phase motors to spin backwards possibly damaging them.

NOTICE:

If for any reason during the check out procedure the

voltage and frequency are not correct, depress the STOP/

RESET button and correct the trouble before proceeding.

4. Stopping - There are two ways to stop the unit when it is

in the manual mode. Pressing the STOP/RESET button will

stop the unit immediately. Pressing the AUTO mode button

will stop the unit but only after the cool down timers have

timed out and there is no remote start signal being sent to

the unit.

AUTO MODE

To activate the automatic start mode you will just need to

depress the AUTO button, the LED indicator beside the

button confirms that the unit is in automatic mode.

To test the Automatic Transfer Switch, follow the instruction

on the operator’s manual that came with the transfer

switch. If you get a fault during the initial start up or prior

to start up, it is most likely a false warning light. Simply reset

the ATS start over.

Once you have completed testing of the ATS, be sure you

ALWAYS leave the system in the standby mode,unless

servicing the unit. For standby operation, press the AUTO

button on the front of the control. The green light should

light up next to the AUTO button.

NOTE: For setting the exerciser circuit, for all ATS, see the

operator’s manual shipped with the ATS.

OPM-109/D

MAINTENANCE SCHEDULE

ISUZU

SERVICE INTERVALS

Check Engine Oil Level Daily

Check Coolant Level and for Leakage Daily

Check Air Filter Daily

Check Electrolyte Level in Battery and Clean Terminals 90 Days

Drain Water from Fuel Pre-Filter Daily

Check Belts and Belt Tension Daily

Check Preheating Operation Daily

Change Oil - Initial

- After Initial

50 Hours

250 Hours

Change Oil Filters - Initial

- After Initial

50 Hours

500 Hours

Change Fuel Filters 500 Hours

Check Exhaust System for Damage 180 Days

Clean Fuel Tank 180 Days

Change Air Filter (depending on conditions) 600 Hours

Check Valve Clearance 1000 Hours

Clean Crankcase Ventilation Valve 1500 Hours

Change Coolant/Clean System 1000 Hours

* There are additional maintenance items and explanations

in the engine operator’s manual. Read thoroughly before

operating this unit.

FIAT

SERVICE INTERVALS

Check Engine Oil Level Daily

Check Coolant Level and for Leakage Daily

Check Air Filter Daily

Check Electrolyte Level in Battery and Clean Terminals 6 Months

Drain Water from Fuel Pre-Filter 150 Hours

Check Belts and Belt Tension 300 Hours

Check Oil Vapor Filter 300 Hours

Change Oil 600 Hours

Change Oil Filters 600 Hours

Change Fuel Filters 600 Hours

Change Fuel Prefilter 600 Hours

Check Exhaust System for Damage 6 Months

Clean Fuel Tank 6 Months

Change Auxiliary Member Belt 1200 Hours

Change Air Filter (depending on conditions) 1200 Hours

Change Coolant 1200 Hours

Change Oil Vapor Filter 2 Years

Clean Turbocharger 1200 Hours

Adjust Play in Valve-Rocker Arms and Pump-Rocker

Arms

1200 Hours

* There are additional maintenance items and explanations

in the engine operator’s manual. Read thoroughly before

operating this unit.

19 OPM-109/D

AVR WIRING

SX460 Automatic Voltage Regulator

The following is a list of connections on the AVR. These

have been factory set and other than voltage adjustment,

should never be changed.

1. Generator AC sensing connection (6,7, & 8)

Field voltage DC (F1 & F2)

2. Voltage adjustment

3. External voltage treatment rheostat.

No external rheostat - link 1 & 2

With external rheostat - 1 & 2 unlinked, connect external

rheostat

leads to 1 & 2

4. AVR input selection

High voltage 208/240/277 - no link between 3 & 4

Low voltage 120 - link 3 & 4

5. Under Frequency Roll Off adjustment

6. Under Frequency Roll Off indication light

7. Frequency selection:

50 Hz operation - link C to 50

60 Hz operation - link C to 60

8. Stability control

7 6 F1 F2

TROUBLESHOOTING TABLE

Problem Possible Causes

Unit will not crank when power

fails

Digital genset not in AUTO

Transfer control switch not in

AUTOMATIC position

Incorrect wiring between ATS and

genset

Defective control relay in ATS

Fuse(s) blown in the DSE 7310 MKII

Defective DSE 7310 MKII

Loose or dirty battery terminals

Defective starter

Defective start solenoid

Low/dead battery

Engine won’t crank Low/dead battery

Blown DC fuses

Defective DSE 7310 MKII

Defective key switch

Loose or dirty battery terminals

Defective starter

Defective start solenoid

Locked up engine genset

Defective engine harness

Improper battery voltage to start

solenoid,

fuel pump, or fuel solenoid

Engine cranks but will not start Improper fuel delivery to the unit

Fuel supply shut off

Fuel tank empty

Air in the fuel system

Engine fuel solenoid has not opened

Defective fuel pump

Defective fuel solenoid

Defective engine harness

Improper battery voltage to fuel

pump or

fuel solenoid

Engine starts, then stops and

alarm light comes on

Engine oil pressure is low

Engine has high water temperature

Engine has overspeed

Engine has gone into overcrank

No output from AC generator

Loss of speed signal

Loss of run signal

Engine will not come up to

speed after it starts

Insufficient fuel volume getting to

the unit

1. Too small of fuel line

2. Fuel racks not open properly

Governor is defective

AC short in generator components

ATS will not transfer to

Emergency Supply (generator)

No AC generator output

Defective ATS control board. See ATS

manual

Circuit breaker open or defective

ATS will not re-transfer to normal

power

Proper power line not available at line

terminals in ATS panel

Defective ATS control board. See ATS

manual

No AC output from generator Defective diode

Defective voltage regulator

Defective rotor

Defective stator

Defective exciter rotor

Defective exciter stator

AC short in the output leads

Defective/open generator output

breaker

Wiring error

OPM-109/D

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WIRING SIZE TABLE

The table below is based on Table 310.15 (B) (16) un the National Electric Code 2014 edition. Allowable ampacitier of insulated conductors rated 0 through

2000V, 75°C through 90°C. Not more than three current-carrying conductors in Raceway, Cable, or Earth (direct buried). Adjust for 40°C (104°F) ambient

temperature.

Copper

75°C

Copper

90°C

Aluminum

Copper Clad

Aluminum

75°C

Aluminum

Copper Clad Aluminum

90°