Winco DX90F4 Setup guide

WINCO INC. 225 S. CORDOVA AVE. LE CENTER, MN 56057
SERVICE DEPT. 507-357-6831 • SALES DEPT. 507-357-6821
www.wincogen.com
INSTALLATION AND
OPERATORS
DX90F4-
DX350F4
GENERATORS
MANUAL
DSE 7310 MKII ELECTRIC START
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2OPM-115
REV A
TABLE OF CONTENTS
SAVE THESE INSTRUCTIONS 2
SAFETY INFORMATION 3
ANSI SAFETY DEFINITIONS
TESTING POLICY 3
SPECIFICATIONS 4
DX90F4
DX100F4
DX130F4
DX175F4
DX250F4
DX350F4
GENERATOR ENDS
INTRODUCTION 6
PRODUCT DESCRIPTION
PREPARING THE UNIT 7
UNPACKING
LIFTING THE GENERATOR SET
INSTALLATION 8
GENERAL INFORMATION
COOLANT
INSTALLING THE BATTERY
CONNECTING BATTERY CHARGER & BLOCKHEATER
MOUNTING THE AUTOMATIC TRANSFER SWITCH
A.C. ELECTRICAL CONNECTIONS 10
GROUNDING
RECEPTACLE PANEL
D.C. ELECTRICAL CONNECTIONS 11
DC INTERCONNECTIONS TO THE ATS
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.
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 # ________________________________________
STARTING PROCEDURE 12
SELECTING THE CORRECT VOLTAGE
INITIAL START UP
MAINTENANCE SCHEDULE 14
TROUBLESHOOTING TABLE 15
VOLTAGE REGULATOR WIRING 15
WIRING SIZE TABLE 16
SELECTOR SWITCH WIRING DIAGRAM 17
DX90-DX130
DX175
DX250
DSE 7310 MKII WIRING DIAGRAM 20
DX90F4-DX130F4
DSE 7310 MKII WIRING DIAGRAM 21
DX175F4-DX350F4
THREE PHASE WIRING - DELTA 22
THREE PHASE AC WIRE HIGH AND LOW WYE 22
SINGLE PHASE AC WIRING - 4 LEAD 22
ENGINE WIRING HARNESS 23
DX90F4-DX130F4
DX175F4-DX350F4
12 MONTH LIMITED WARRANTY 24

3OPM-115 REV A
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,
oors).
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re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qualied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mufers,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re.Pleasereadallsafety
instructions carefully before installation or use. Keep these instructions
handy for future reference. Take special note and follow all warnings on
the unit labels and in the manuals.
ANSI SAFETY DEFINITIONS
DANGER:
DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury. This signal word is to be
limited to the most extreme situations.
WARNING:
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION:
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may also be used to
alert against unsafe practices.
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re.
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amenearthegeneratorsetorfuel
tank.
D. Keepareextinguishernearbyandknowitsproperuse.
Fire extinguishers rated ABC by NFPA are appropriate.
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.
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specied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.

4OPM-115
REV A
SPECIFICATIONS
DX90F4
Generator
Wattage 67,000 90,000 90,000 90,000
kVa 67 113 113 113
Volts 120/240 120/208 120/240 277/480
Phase Single Three Three Three
PF 1.0 .80 .80 .80
Amps 281 312 256 135
CBSize 400 400 400 150
Hertz 60 60 60 60
Engine
Model FPT N45 TM2 4.5L
Starting System 12 Volt
Mufer Standard
FuelConsumption(fullload) 6.94Gal/Hr
EngineFluidSpecications
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
DX100F4
Generator
Wattage 79,000 105,000 100,000 115,000
kVa 79 131 125 143
Volts 120/240 120/208 120/240 277/480
Phase Single Three Three Three
PF 1.0 .80 .80 .80
Amps 328 364 294 172
CBSize 400 400 400 175
Hertz 60 60 60 60
Engine
Model FPT N67 TM1X 6.7L
Starting System 24 Volt
Mufer Standard
FuelConsumption(fullload) 7.71Gal/Hr
EngineFluidSpecications
Fuel ASTM D-975 -1D or 2D
EN590 or equivalent
Oil Type SEE LUBRICATION SECTION
Oil Capacity 17.9 Quarts
CoolingSystem 50/50mix
DX130F4
Generator
Wattage 109.000 130,000 123,000 130,000
kVa 109 162 154 102
Volts 120/240 120/208 120/240 277/480
Phase Single Three Three Three
PF 1.0 .80 .80 .80
Amps 453 450 370 195
CBSize 400 400 400 400
Hertz 60 60 60 60
Engine
Model FPT N67 TM1X 6.7L
Starting System 24 Volt
Mufer Standard
FuelConsumption(fullload) 8.8Gal/Hr
EngineFluidSpecications
Fuel ASTM D-975 -1D or 2D
EN590 or equivalent
Oil Type SEE LUBRICATION SECTION
Oil Capacity 17.9 Quarts
CoolingSystem 50/50mix
DX175F4
Generator
Wattage 94,000 175,000 175,000 175,000
kVa 94 219 219 219
Volts 240/480 120/208 120/240 277/480
Phase Single Three Three Three
PF 1.0 .80 .80 .80
Amps 395 607 525 263
CBSize 600 600 600 600
Hertz 60 60 60 60
Engine
Model FPT N67 TE2 6.7L
Starting System 24 Volt
Mufer Standard
FuelConsumption(fullload) 12.42Gal/Hr
EngineFluidSpecications
Fuel ASTM D-975 -1D or 2D
EN590 or equivalent
Oil Type SEE LUBRICATION SECTION
Oil Capacity 17 Quarts
CoolingSystem 50/50mix

5OPM-115 REV A
DX250F4
Generator
Wattage 137,000 250,000 250,000 250,000
kVa 137 312 312 312
Volts 240/480 120/208 120/240 277/480
Phase Single Three Three Three
PF 1.0 .80 .80 .80
Amps 570 868 752 376
CBSize 1000 1000 1000 1000
Hertz 60 60 60 60
Engine
Model FPTC87TE1D8.7L
Starting System 24 Volt
Mufer Standard
FuelConsumption(fullload) 16.98Gal/Hr
EngineFluidSpecications
Fuel ASTM D-975 -1D or 2D
EN590 or equivalent
Oil Type SEE LUBRICATION SECTION
Oil Capacity 29.6 Quarts
CoolingSystem 50/50mix
DX300F4
Generator
Wattage 300,000 300,000 300,000
kVa 375 375 375
Volts 120/208 120/240 277/480
Phase Three Three Three
PF .80 .80 .80
Amps 1041 900 451
CBSize 800 800 800
Hertz 60 60 60
Engine
Model FPT C10 TE1D 10.3L
Starting System 24 Volt
Mufer Standard
FuelConsumption(fullload) 20.2Gal/Hr
EngineFluidSpecications
Fuel ASTM D-975 -1D or 2D
EN590 or equivalent
Oil Type SEE LUBRICATION SECTION
Oil Capacity 37 Quarts
CoolingSystem 50/50mix
DX350F4
Generator
Wattage 350,000 350,000 350,000
kVa 438 438 438
Volts 120/208 120/240 277/480
Phase Three Three Three
PF .80 .80 .80
Amps 1215 1051 526
CBSize 800 800 800
Hertz 60 60 60
Engine
Model FPT C13 TTE3X 13L
Starting System 24 Volt
Mufer Standard
FuelConsumption(fullload) 24.5Gal/Hr
EngineFluidSpecications
Fuel ASTM D-975 -1D or 2D
EN590 or equivalent
Oil Type SEE LUBRICATION SECTION
Oil Capacity 77 Quarts
CoolingSystem 50/50mix
GENERATOR ENDS
NOTE: Review the Stamford Newage nameplate on your generator.
Some custom applications use other models. Check the generator
nameplate for actual model number. Additional generator information
available on line at www.wincogen.com under Service Support.
StamfordNewageModel#UCI274C(12lead)
Voltage Regulator SX460
Rotor Resistance 1.12 ohms
StatorResistance 0.059ohms/phase
Excitor Stator Resistance 20.0 ohms
ExcitorRotorResistance 0.091ohms/phase
StamfordNewageModel#UCI274D(12lead)
Voltage Regulator SX460
Rotor Resistance 1.26 ohms
StatorResistance 0.044ohms/phase
Excitor Stator Resistance 20.0 ohms
ExcitorRotorResistance 0.091ohms/phase
StamfordNewageModel#UCI274E(12lead)
Voltage Regulator SX460
Rotor Resistance 1.334 ohms
StatorResistance 0.0317ohms/phase
Excitor Stator Resistance 20.0 ohms
ExcitorRotorResistance 0.091ohms/phase

6OPM-115
REV A
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eld
design.Thegeneratorisconnectedtotheengineywheelviaexible
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, the DX250-350 are 24 Volt systems. 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eldfrom0to30minutesbyyourinstaller.Otherfeatures,timing
StamfordNewageModel#UCI274H(12lead)
Voltage Regulator SX460
RotorResistance  1.82ohms
StatorResistance  0.0155ohms/phase
Excitor Stator Resistance 20.0 ohms
ExcitorRotorResistance 0.091ohms/phase
StamfordNewageModel#HCI434D(12lead)
Voltage Regulator MX341
Rotor Resistance 1.05 ohms
StatorResistance  0.00124ohms/phase
ExcitorStatorResistance 18.0ohms
ExcitorRotorResistance 0.068ohms/phase
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identies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.
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 specied 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specied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

7OPM-115 REV A
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.
DD = Diesel
XX=Prime/SwitchableVoltage
175 Generator Output Rating in kW
FEngine Manufacturer: F = FPT
4Number of Generator Poles
-Base Unit - Options Separator
XSee ES-503 OR ES-504
A
HOUSING TYPE
A=SoundAttenuated/WeatherProtective
* = No Housing
MFuelTankSize:S=Small;M=Medium;L=Large;
* = None
TT=Trailer;*=None
D
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
TRAILER/HOUSING
These switchable voltage generators are normally shipped fully
enclosed&mountedonatrailer.Thesizeofthetrailermayvaryby
bothmodelandfueltanksizerequirements.AllthetrailersareDOT
approvedandyoushouldreceiveacerticateoforiginwitheachunit.
This will allow you to register the equipment and obtain tags from your
state. If you should encounter any problems registering the trailer,
contacttheWINCOServiceDeptat507-357-6831.
AUTOMATIC TRANSFER SWITCH
AwallmountedASCO300AutomaticTransferSwitch(ATS)designed
forinsideoroutsideinstallation.ThetransferswitchisUL1008
approved. A fourteen day electronic exerciser circuit is installed
in the ATS as standard equipment. The ATS also contains the power
failure sensing circuitry necessary to start and stop the engine
generator set. The transfer switch is also equipped standard with a 3
second start delay, and a 15 second transfer delay to allow the engine
to warm up before transferring the load to the generator. When the line
power is restored the ATS has a 5 minute transfer delay to allow the
incomingutilitytostabilizebeforetransferringbacktolinepowerand
then an additional 1 minute engine cool down delay before the engine
shuts down. Read and understand the ATS owners manual before
installing, servicing or operating the transfer switch.
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le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specication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 uid levels before operating. See engine manufacturer’s
instruction manual for recommended oil requirements before initial
starting.
Once generator set is on-site:
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.
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,congurations,options,weights,site
conditions,andavailablematerialhandlingequipment,specic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 lled 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.

8OPM-115
REV A
INSTALLATION
WARNING: PERSONAL INJURY:
PERSONAL INJURY - Before proceeding with the installation, be sure
the DSE7310 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 supplied as weather enclosed, trailered
packages.TheDOTcertiedtrailerisrequiredformobileapplications.
Consultaqualied,licensedelectricianorcontractortoinstallandwire
the gen-set. The installation must comply with all national, state, and
local codes. The factory weather enclosures are acoustical housing
intended for outdoor use only. Units are not intended to be used
indoorsandnosupportisavailabletoassistinre-engineeringnished
packaged units.
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nalizing
your installation plans.
FUEL REQUIREMENTS
During periods of normal operations, these engines will all use #2 die-
sel fuel. Seasonally blended fuel should be used during time of extreme
cold to ensure proper engine operation. See the engine operator’s
manualformorespecicinformationonrequirements.
NOTE: When starting the unit for the time it may be necessary to prime
the engine before engine before engaging the starter. The internal tank
on the unit was not used during testing so there may be some air in the
fuel lines that will have to be bled out.
LUBRICATION
Before starting the engine, check the oil level in the crankcase. If
itislow,rell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lledwillcauseexcessiveenginewearandshorten
its useful life.
COOLANT
Before starting the engine, check the coolant level in the radiator. If
itislow,rellasspeciedintheenginemanufacturer’smaintenance
instructions.Theradiatorshouldbelledtoabout1inchbelowtheller
neck. For additional information on engine coolant requirements, see
manufacturer’s maintenance instructions.
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.
These units require 4D batteries, The DX90-175 is a 12 volt system
and requires a single battery and the DX250-350 are 24 volt and
require 2 batteries. The batteries should be rated at a minimum of
1100 CCA. Installation of the highest CCA rated battery, within the
correct BCI group, will increase cold weather starting performance.
Gel batteries should not be used with the battery tender installed in the
generator enclosure.
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 re. 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 rst and then connect
the battery negative cable. When removing the battery cables
from the battery, reverse the procedure, disconnect the negative
rst and then the positive cable.
5. Be sure all connections are tight and coat the terminals and cable
ends with dialectic grease.

9OPM-115 REV A
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, ush 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
ushed with water and the area dried.
DANGER: EXPLOSIVE FIRE RISK:
1. Never smoke when near batteries.
2. Do not cause a ame or spark in the battery area.
3. Always discharge static electricity from your body before touching
batteries by rst 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specic
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.
CONNECTING BATTERY CHARGER & BLOCKHEATER
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rstmode,knownasBulk
charging, the charging current is limited to 10 Amps at a voltage of
upto14/27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ashing.Thechargingvoltageisheldat14/27Voltsand
thechargingrategraduallyreducestheamountofcurrent(Amps)
owingtothebatteryto100%chargedstate.Thebatterycanbeleft
onthismodeindenitely.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 with the United
States National Electric Code. It is suggested that this circuit be fused
for 15 amps. The blockheaters on these units are 1000 watt on the
DR175 and 2250 watt on the larger units. The 2250 watt heaters and
will require a separate 20 amp GFCI fused circuit. They are labeled
Battery Charger Circuit and Blockheater Circuit.
The engine blockheater installed on this unit should also be plugged
in this receptacle. The block heater is thermostatically controlled and
when plugged in will maintain the engine coolant temperature between
100 and 120 degrees F.
MOUNTING THE AUTOMATIC 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specic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,rst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specic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.

10 OPM-115
REV A
L1, L2, & L3 POWER OUTPUT LUGS:
Theselugswillhandlewiresizesfrom#4to600MCMandshouldbe
torqued to 22 ft. lbs. Two lugs per generator output leg are provided for
your use. These lugs are isolated from the generator frame.
Inthe120/240V3-Phcongurationwiththewildleg(208lineto
neutral)iswiredtotheL2position.ALSONOTETHATBECAUSEOF
A CONFIGURATION PROBLEM, THE DEEP SEA CONTROLLER
WILL SHOW THE WILD LEG ON L1 BUT IT IS WIRED TO THE L2
POSITION.
WARNING: PERSONAL DANGER:
This unit is shipped with the neutral and ground unbonded. If the unit
is to be used as a stand-alone generator, you must bond neutral and
ground together either at this terminal block or somewhere in your
system.
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.
RECEPTACLE PANEL
A: 20 AMP CIRCUIT BREAKERS:
2-20 Amp circuit breakers provide circuit breaker protection for the 2-20
Amp GFCI 120V receptacles.
B:20AMP/120VGFCIRECEPTACLES:
These2-20Amp(NEMA5-20)GFCIprotectedreceptaclesare
poweredonlywhentheselectorswitchisinthe240or208Vposition.
Theyaredeadwhenthevoltageselectorswitchisinthe480Vposition.
C: 50 AMP CIRCUIT BREAKERS:
2-50 Amp circuit breakers provide circuit breaker protection for the 2-50
Amp120/240Vtwistlockreceptacles.
A
C
B
D
E
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.
This AC terminal block is covered by a lockable access cover. Access
for routing the wires into the terminal block is provided via a small
access door just to the left of the main control panel door. You will also
ndyourconveniencereceptacleslocatedbehindthissmalldoor.All
receptacles located here have their own circuit breaker for protection.
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 1200 Amp terminal block lugs on the 300-350kW will handle wire
sizes#3/0to600MCMandshouldbetorquedto28ft.lbs.
The1000Ampterminalblocklugsonthe250kWwillhandlewiresizes
#3/0to500MCMandshouldbetorquedto28ft.lbs.(Ratedfor900
AmpforAL)
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 #6 AWG to 300 MCM and should be torqued to 22 ft. lbs.
Two lugs are provided for your use.

11OPM-115 REV A
D.C. ELECTRICAL CONNECTIONS
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.
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 Ground and Start. The wire in terminal
labeled 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 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. The
terminal blocks are designed to use terminal lugs on all wires and the
screws should be torqued to 9.6 in. lbs.
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
D:50AMP120/240VTWISTLOCKRECEPTACLES:
2-50 Amp receptacles are powered only when the selector switch is in
the208or240Vposition.Theyaredeadwhentheselectorswitchisin
the480Vposition.Thesetworeceptaclesare4-wire120/240V.(Mating
plugisaCS6365)
E: 15 AMP 120V REVERSE PLUG:
This plug is provided to power the block heater and battery charger
mounted inside the unit when the unit is used for standby. It also allows
battery charging during periods of long term storage.
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.
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 MKII 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. This display can be used to
meet the remote annunciation requirements of NFPA 110 Standards.
(This feature meets the annunciations requirements in applications
requiringNFPA110leveloneprotection).
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 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
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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WKHUHPRWHVWDUWUHOD\LVFORVHGDJDLQ
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
*************
***** WARNING *****
*************
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you make any DC interconnections.
*******CAUTION******
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ASCO 185 UL SWITCH
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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

12 OPM-115
REV A
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congured)
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conguration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.
SELECTING THE CORRECT VOLTAGE
A variety of three phase voltages are available from the three position
selector switch. The three basic connection patterns are Delta
(120/240).LoworParallelWye(120/208),andHighWye(277/480).
Before wiring and starting this unit, be sure you have the selector
switch set for the right voltage. You must depress the safety switch
below the selector switch to change the position of the voltage selector
switch. If the unit is running, depressing this switch will shutdown the
engine-generator set.
At the same time you are making the voltage selection, you must also
adjust the setting on the mainline circuit breaker to give the proper
breaker protection. See the following diagram for proper adjustments.
The DX90-DX130 have a two circuit breaker system installed on them,
you must ensure the correct breaker is turned closed.
If you have any doubts also the voltage in your area, compare your
incoming power or load name plates to the following voltage tables.
1. 120/240Voltthreephase*(Delta/Seriesconguration)
Thiscongurationwillproducethefollowingline-to-lineandline-to-
neutral voltage. In this selector switch position, all of the receptacles
on the front panel are powered.
G1 - G2 - G3 240V three phase
G1 - G2 240V single phase
G2 - G3 240V single phase
G1 - N 120V
G2-N 208V
G3 - N 120V
WARNING: POTENTIAL EQUIPMENT DAMAGE:
ThisDeltacongurationhasawildlegthatproduces208Vlineto
neutral on G2. Be sure when connecting to your panel or load that you
match the wild phase on the generator to the wild phase in your panel
orload.Failuretodosowillresultin120Vdevicesreceiving208V.you
must also match your rotation.
*120/240Vsinglephaseoutputalsousesthisswitchposition.When
connectingforsinglephase,thewildlegof120/240Vthreephase
connectionisnotused(G2).

13OPM-115 REV A
2. 120/208Voltthreephase(Low/ParallelWyeconguration)
thiscongurationwillproducethefollowingline-to-lineandline-to-
 neutralvoltage.Useofthisselectorswitchpositionallowsutilization
of the 120V receptacle only. The 240V receptacles cannot be used
asthevoltageisonly208V.
G1-G2-G3 208Vthreephase
G1-G2 208Vsinglephase
G2-G3 208Vsinglephase
G1-G3 208Vsinglephase
G1 - N 120V
G2 - N 120V
G3 - N 120V
3. 277/480Voltthreephase(High/SeriesWyeconguration)
Thiscongurationwillproducethefollowingline-to-lineandline-to-
neutral outputs.
NOTE: Convenience receptacles
The 120 or 240 Volt receptacles are disconnected with the selector
switch in this position.
G1-G2-G3 480Vthreephase
G1-G2 480Vsinglephase
G2-G3 480Vsinglephase
G1-G3 480Vsinglephase
G1 - N 277V
G2 - N 277V
G3 - N 277V
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.
After completing the previous checklist, the engine-generator set is
ready for initial start-up.
MANUAL MODE
WARNING: EQUIPMENT DAMAGE:
Before attempting to start this unit, complete your prestart checklist and
ensure the generator mainline circuit breaker is in the proper position
prior to starting. Starting this unit without it being properly connected,
can cause serious personal injury or equipment damage.
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 a start signal to the ECU on the engine. The engine ECU
willthenenergizethefuelsolenoidandstartthecrankingcycle(10
secondsonand15secondsoff)
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. All engine functions are controlled by the ECU on the engine. The
ECU on the engine will send information signals to the DSE 7310 MKII
via the CAN connections to indicate oil pressure, water temperature,
etc. for the display on the engine control. All shutdown functions are
controlled by the ECU on the engine, what you see displayed on the
DSE 7310 MKII display is what is happening inside the ECU on the
engine.
The AC ouptut readings displayed on the DSE 7310 MKII are collected
through the AC interface harness wired in the generator control box.
Any shutdowns related to the AC output are not a function of the engine
ECU, but are based on information collected in the DSE 7310 MKII via
this AC harness.
4. 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 to 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58.5to62
hertz(Hz).
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

14 OPM-115
REV A
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).
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.
5. 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conrms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.
MAINTENANCE SCHEDULE
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Prelter 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.

15OPM-115 REV A
TROUBLESHOOTING TABLE
NOTE: Before doing any trouble shooting, check the digital display on
the DSE 7310 MKII. Normally, it will tell why the unit has failed. This
will shorten your trouble shooting time and in many cases, prevent the
replacement of parts that may not be defective.
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
Insufcient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
VOLTAGE REGULATOR WIRING
AS440 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.
VOLTS
To adjust generator output voltage.
Clockwise to increase voltage.
STABILITY
To prevent voltage hunting.
Clockwise to increase the dampening effect.
STANDARD CONNECTIONS
Terminals1&2willbettedwithashortinglinkifnohandtrimmeris
required.
Terminals La & Lb are linked only for special low voltage applications.
UFRO - Under Frequency Roll Off
Terminal S1 is connected to the C.T., S2 on the AVR.
DROOP - Normally preset in the works to give 5% voltage droop at full
loadzeropowerfactor.
Terminal A1 is connected to the AVR 0 Volts. Positive on A2 increases
excitation, negative on A2 decreases excitation.
TRIM - allows the user to adjust the sensitivity of the input.
LED Indicator Light - indicates over excitation condition or under speed
running.
MX341 Automatic Voltage Regulator
Under normal conditions only two adjustments are made to the voltage
regulator.
VOLTS
To adjust generator output voltage.
Clockwise to increase voltage.
STABILITY
To prevent voltage hunting.
Clockwise to increase the
dampening effect.
STANDARD CONNECTIONS
(TopRow,RighttoLeft)
1 -2 Are linked together.
2 - Lead #9 from AC terminal block.*
3-Lead#8fromACterminalblock.*
X - F1 from generator exciter
XX - F2 from generator exciter
P4, P3, P2 all come from the PMG
* voltage between these to leads must be between 190 & 264.
(Centertappedon480Volt)
LED
Indicator
Light
FITTING AND OPERATING
©2006 3 TD_AS440 AVR_03.09_04_GB
SUMMARY OF AVR CONTROLS
CONTROL FUNCTION DIRECTION
VOLTS TO ADJUST GENERATOR OUTPUT VOLTAGE CLOCKWISE INCREASES OUTPUT VOLTAGE
STABILITY TO PREVENT VOLTAGE HUNTING CLOCKWISE INCREASE THE DAMPING EFFECT
STAB SWITCH TO OPTIMISE TRANSIENT PERFORMANCE SEE TABLE ABOVE
UFRO TO SET THE UFRO KNEE POINT CLOCKWISE REDUCES THE KNEE POINT FREQUENCY
DROOP TO SET THE GENERATOR DROOP TO 5% AT 0PF CLOCKWISE INCREASES THE DROOP
VTRIM TO OPTIMISE ANALOGUE INPUT SENSITIVITY CLOCKWISE INCREASES THE GAIN OR SENSITIVITY
EXC TRIP TO SET OVER EXCITATION TRIP CUT OFF LEVEL CLOCKWISE INCREASES THE CUT OFF LEVEL
ADJUSTMENT OF AVR CONTROLS
VOLTAGE ADJUSTMENT
The generator output voltage is set at the factory, but
can be altered by careful adjustment of the VOLTS
control on the AVR board, or by the external hand
trimmer if fitted. If major adjustment is necessary or
you lose stability, follow the ‘VOLTAGE SETUP
PROCEDURE’.
Terminals 1 and 2 on the AVR will be fitted with a shorting
link if no hand trimmer is required. Terminals La and Lb are
linked only for special low voltage applications.
WARNING! Do not increase the voltage above the rated
generator voltage. If in doubt, refer to the rating plate
mounted on the generator case.
WARNING! Do not ground any of the hand trimmer
terminals as these could be above earth potential. Failure
to observe this could cause equipment damage.
WARNING!
If a replacement AVR has been fitted or re-setting of the
VOLTS adjustment is required, turn the VOLTS control
fully anti-clockwise before running generator.
VOLTAGE SETUP PROCEDURE
For major adjustments and replacing the AVR.
Read and understand this procedure before
attempting to follow it.
1. Before running generator, turn the VOLTS control
fully anti-clockwise.
2. Turn remote volts trimmer (if fitted) to midway
position.
3. Turn STABILITY control to midway position.
4. Connect a suitable voltmeter (0-300V ac) across
line to neutral of the generator.
5. Start generator set, and run on no load at nominal
frequency e.g. 50-53Hz or 60-63Hz.
6. If the red Light Emitting Diode (LED) is illuminated,
refer to the Under Frequency Roll Off (UFRO)
adjustment.
7. Carefully turn VOLTS control clockwise until rated
voltage is reached.
8. If instability is present at rated voltage, refer to
stability adjustment, then re-adjust voltage if
necessary.
9. Voltage adjustment is now completed.
REFER TO GENERATOR WIRING DIAGRAM
FOR CONNECTION DETAILS
F2 F1 7 8 8 Z2
S1
S2
A1
A2
A
S440
Trim
Droop
Volts
Stability
Selection
UFRO
Frequency
Selection
Indicator LED
Stab
60Hz
50Hz
1
2
3
Lb
La
ABCD
Stability Selection Table
No. Power range Response
B-D < 100kW Slow
A-C < 100kW Fast
B-C 100-550kW Fast
A-B > 550kW Fast
Hand trimmer terminals. Remove
link before fitting hand trimmer.
Link must be fitted when hand
trimmer is not required.
Exc
Trip
8 and Z2 – linked for
normal operation
235040-00 60708-166
VOLTAGE REGULATOR WIRING
K1 K2 P2 P3 P4 XX X 3 2 2 1
A1
A2
S1
S2
1
2
3
4
5
6
7
8
C B A 3 2 1
MX341
Trim
Droop
Volts
Stability
Selection
UFRO
Frequency
Selection
Indicator
LED Stability
K1-K2
Power isolation link
(normally fitted)
REFE
R
DIP
EXC.
TRIP
> 550kW
< 90kW
90-550kW
4P60H
z
4P50H
z
No link 6P50Hz
6P60H
z
Sensing
links
standard
positions
Under normal conditions only two adjustments
are made to the voltage regulator.
VOLTS - To adjust generator output voltage.
Clockwise to increase voltage.
STABILITY - To prevent voltage hunting.
Clockwise to increase the
dampaning effect.
STANDARD CONNECTIONS
(Top Row, Right to Left)
1 -2 Are linked together.
2 - Lead #9 from AC terminal block.*
3 - Lead #8 from AC terminal block.*
X - F1 from generator excitor
XX - F2 from generator excitor
P4, P3, P2 all come from the PMG
* voltage between these to leads
must be between 190 & 264.
(Center tapped on 480 Volt)
SX460 Automatic Voltage Regulator
The following is a list of connections on the AVR. These
have been factory set and other that volt adjustment should
never have to be changed.
1. Generator AC sensing connection (6, 7, 8)
Field voltage DC (F1 & F2)
2. Voltage Adjustment
3. External voltage adjustment 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 volt link 3 & 4.
5. Under Frequency Roll Off adjustment
6. Under Frequency Roll Off indication LED
7. Frequency selection:
50 Hz operation Link C to 50
60 Hz operation Link C to 60
8. Stability control
MX341 Automatic Voltage Regulator

16 OPM-115
REV A
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°
Wire Type:
RHW, THHW, THW, THWN,
XHHW, USE, ZW
Wire Type:
TBS, SA, SIS, FEP, FEPB, MI, RHH,
RHW-2, THHN, THHW, THW-2, XHH,
XHHW, XHHW-2, ZW-2
SIZE AWG
OR KCMIL
Wire Type:
RHW, THHW, THW, THWN,
XHHW, USE
Wire Type:
TBS, SA, SIS, THHN,
THW-2, THWN-2, RHH, RHW-2, USE-2,
XHH, XHHW, XHHW-2, ZW-2
44
57
75
88
101
114
132
154
176
202
224
251
273
295
334
370
405
418
431
458
480
519
550
572
585
50
68
86
100
118
137
155
177
205
237
264
291
319
346
391
432
473
487
505
532
560
605
642
669
683
8
6
4
3
2
1
1/0
2/0
3/0
4/0
250
300
350
400
500
600
700
750
800
900
1000
1250
1500
1750
2000
35
44
57
66
79
88
106
119
136
158
180
202
220
238
273
299
330
339
348
374
392
427
458
480
493
41
55
68
77
91
105
123
137
159
187
209
232
255
278
319
350
382
396
410
437
455
496
532
560
573
For additional information, see table 310.15 of the National Electric Code.

17OPM-115 REV A
SELECTOR SWITCH WIRING DIAGRAM
DX90-DX130

18 OPM-115
REV A
DX175

19OPM-115 REV A
DX250

20 OPM-115
REV A
DX90F4-DX130F4
DSE 7310 MKII WIRING DIAGRAM