Winco PSS150/A Setup guide

INSTALLATION AND
OPERATORS MANUAL
PSS150/A
GENERATOR
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MODEL __________________________________________________
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16200-017

2
OPM-124/B
TABLE OF CONTENTS
SAVE THESE INSTRUCTIONS 2
TESTING POLICY 2
SAFETY INFORMATION 3
SPECIFICATIONS 4
INTRODUCTION 5
PRODUCT DESCRIPTION
PREPARING THE UNIT 6
UNPACKING
INSTALLATION 7
ENGINE-GENERATOR SET MOUNTING
FUEL INSTALLATION 7
INSTALLING THE FUEL LINE
LIQUID PROPANE VAPOR (LP)
NATURAL GAS (NG)
FUEL PRESSURE
FUEL PRESSURE TABLES
NG/LP FUEL CONVERSION
INSTALLING THE BATTERY 10
SERVICING BATTERIES
BATTERY CHARGING
CONNECTING BATTERY CHARGER & BLOCK HEATER
AC CONNECTIONS 12
GROUNDING
MOUNTING THE ATS
DC CONNECTION 14
DC INTERCONNECTIONS TO ATS
STARTING PROCEDURE 15
INITIAL START UP
AVR WIRING 17
TROUBLE SHOOTING TABLES 18
MAINTENANCE 19
MAINTENANCE SCHEDULE
PREVENTATIVE MAINTENANCE
AUTOMATIC TRANSFER SWITCH
ENGINE-GENERATOR SET
COLD WEATHER OPERATION
AC WIRING 20
3-PH HIGH WYE 277/480V
3-PH LOW WYE120/208V
1-PH 120/240V DOUBLE DELTA
3-PH DELTA 120/240V
ENGINE HARNESS SCHEMATIC 22
DSE 7310 MKII WIRING DIAGRAM 23
LIMITED WARRANTY 24
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.
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.

3OPM-124/B
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.
SAFETY DEFINITIONS
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in death
or serious injury.
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.
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.
DANGER: 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 for your
application.
DANGER: 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).
WARNING: 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.
E. Store fuel only in an approved container, and
only in a well ventilated area.
F. Follow local codes for closeness to combustible
material.
CAUTION: PERSONAL INJURY
The muffler becomes very hot during operation and
for a period after the unit has been turned off. Do not
touch the muffler until it has completely cooled off.
CAUTION: 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.
CAUTION
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.
CAUTION
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.

4
OPM-124/B
SPECIFICATIONS
LP Gas
Wattage 125,000 125,000 125,000 125,000
Volts 120/240 120/208 120/240 277/480
kvA 125 156 156 156
Phase Single Three Three Three
Amps 520 434 375 187
CB Size Adjustable Circuit Breaker
Hertz 60 60 60 60
Natural Gas
Wattage 125,000 150,000 150,000 150,000
Volts 120/240 120/208 120/240 277/480
kvA 125 187 187 187
Phase Single Three Three Three
Amps 520 521 452 226
CB Size Adjustable Circuit Breaker
Hertz 60 60 60 60
Engine
Model PSI 8.8L
Starting System 12 Volt
Muffler Standard
Fuel Consumption (full
load)
LP
NG
19.83 GAL/HR - 1,832,410
BTU/HR
2,014 FT³/HR - 2,014,300
BTU/HR
CAUTION: EQUIPMENT DAMAGE
The adjustable breaker has an Instant Trip that must be
adjusted appropriately. Failure to set the Instant Trip
will result in damage to the unit. See page 10 of this
manual.
Generator Testing Resistance
Note: Review the Stamford Newage nameplate on your
generator before selecting the correct information below.
Model Stamford UCI274G1L
Winding Group 311
Resistances:
Rotor 1.69 Ohms @20°C
Stator (L-L) 0.01 Ohms Per Ph @ 20°C
Exciter Rotor (L-L) 0.182 Ohms Per Ph @ 20°C
Exciter Stator (L-L) 20.00 Ohms @ 20°C
Aux Winding 2.6 Ohms @ 20°C
Voltage Regulator AS440

5OPM-124/B
INTRODUCTION
PRODUCT DESCRIPTION
The Package Standby System is designed to automatically
provide standby power to unattended loads during
electrical outages. Upon interruption of normal electrical
service, the Packaged Standby System electrical control
circuits will automatically start the engine. The generator
will produce electrical power and the Automatic Transfer
Switch (ATS) will automatically transfer the electrical loads
to the engine-generator set. Upon restoration of normal
electrical service the emergency transfer switch will sense
return of the normal commercial power. The Automatic
Transfer Switch will transfer the load back to the normal
commercial power source. The engine control circuits will
begin a cool-down cycle, after which the fuel supply will be
shut off and the engine ignition system disabled.
These packaged standby systems consist of two major
components:
1. 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.
MINIMUM
UNIT VOLTAGE ATS AMPERAGE
PSS150-3 120/240 600
PSS150-4 120/208 500
PSS150-17 120/240 500
PSS150-18 277/480 225
2. ENGINE / GENERATOR
The engine generator set consists of a PSI 8.8L, Industrial,
V8, liquid cooled engine equipped to run on LP/NG fuel.
The engine operates at 1800 rpm and frequency regulation
is maintained by the electronic governor within .5 cycles
variation, from no load to rated load. The generator is
a single bearing, direct drive, rotating field design. The
generator is connected to the engine flywheel via flexible
drive disks. The engine generator is available mounted
in a weather proof enclosure for outside installation.
Connection boxes are provided to all customer connections
(both AC output and DC control). A customer supplied
12 Volt, 900 CCA (BCI group 31) battery is required to
complete the installation. Engine operation is controlled
by a Deep Sea (DSE) MKII engine mounted in the engine
generator enclosure.
NOTICE:
These units will automatically transfer if a power outage
occurs while running in an exercise mode.

6
OPM-124/B
PREPARING THE UNIT
UNPACKING
CAUTION: EQUIPMENT DAMAGE
When you unpack your new generator, be sure to
remove all of the information sheets and manual from
the carton.
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
These units are shipped with oil. Be sure to check oil
levels before operating. See engine manufacturer’s
instruction manual for recommended oil requirements
before initial starting.

7OPM-124/B
INSTALLATION
WARNING
Before proceeding with installation, be sure the
operation selector switch is in the stop position and the
battery disconnected.
These engine generator sets are designed to be mounted
on a pad where there is proper ventilation. The transfer
switch is mounted next to your electrical entrance or
distribution panel inside or outside the building. Consult
a qualified, licensed electrician or contractor to install and
wire the transfer switch. The installation must comply with
all national, state and local codes. Before beginning the
installation process check the rating of the generator set
and its transfer switch rating. Be certain they can handle
the intended load and are compatible with the entrance
voltage, phase and current ratings. 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.
ENGINE-GENERATOR SET MOUNTING
WARNING: PERSONAL INJURY
The enclosures on these units can become very hot
adjacent to the exhaust areas. Special care must be
taken when installing these units to insure that the risk
of contact by people is minimized.
The unit’s main frame should be bolted to a pad that meets
local code. Various materials, including concrete and
composites, are acceptable as long as they are structurally
sound supporting the weight of the unit and preventing
movement during operation. The mounting holes on the
base of this unit is 0.688” in diameter. The engine-generator
is mounted on a sub-frame which is isolated with special
shock mounts on the main frame. This allows the engine-
generator to vibrate without affecting the control panel on
the main frame.
Do not install any shock mounts between the base frame
and the pad. Engine vibration will be transmitted to the
control panel causing erroneous start/stop cycles and
premature control failure.
These units should be mounted a minimum of 24” from a
structure. This will allow for ample room to maintain and
work on the generator set.
Units must be installed in accordance with all local, state,
and national codes. Consult your local agency for specific
requirements.
FUEL INSTALLATION
The fuel supply should be as close as possible to the
engine. This will reduce the installation cost of fuel runs.
The information in this manual is offered to 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
and information provided be interpreted to conflict with
any local, state or national codes. If in doubt, always consult
your local fire marshal, gas supplier or building inspector.
WARNING: FIRE HAZARD
All fuel runs should be installed by a licensed fuel
supplier.
To connect the fuel line to the generator set you will
connect your incoming fuel line to the 1.25 inch NPT fitting
located on the rear cross-member of the engine-generator
set. This fitting is shipped with a plastic plug installed to
insure the fuel system stays clean. For all vapor fuel systems
the delivery pressure of the fuel to the fuel solenoid on the
unit must be four to six ounces psi (per square inch) or 7 to
11 inches
W.C. (water column). These fuel pressures are critical; failure
to provide the proper pressure can cause many problems
including failure to start, inability to produce full power, or
damage to the equipment.
These generators have been tested with both natural gas
and LP at the factory. Before starting the engine you must
verify it is configured for the proper fuel. See additional
information in the NG/LP conversion section.
INSTALLING THE FUEL LINE
NOTICE: The engine generator sets are properly adjusted
before they leave the factory. The electronic control panel
will indicate if the LP mode is active
NATURAL GAS or LP VAPOR PIPE SIZE
Size of pipe normally required for generators operating on
natural gas or LP vapor. Unit location will determine the
size of fuel line that is required to supply the engine with a
constant fuel pressure and volume.
LIQUID PROPANE VAPOR (LP)
Refer to the tables on the following pages for fuel line size
and recommended tank size. For distances of 25 feet or
over, a two regulator fuel system is recommended. This is
accomplished by installing a primary regulator at the tank
which will reduce the tank pressure down to 10 to 15 lbs.
A low pressure regulator is installed to further reduce the
fuel pressure to the required six (6) oz. operating pressure.
This low pressure regulator must be at least 10 feet from
the engine generator set; any closer installation will require
a larger line be installed to provide a fuel reservoir. This is
also true for the single low pressure regulator, it should
also be a minimum of 10 feet from the unit. If this is not
done, the demand regulator on the unit and the pressure
regulator in the fuel line will interfere with each other.
When the two (2) regulator system is used on LP, a fuel line
size of 3/4 to 1 inch is generally adequate for distances up
to 300 feet from the primary to the low pressure regulator.
Consult your local fuel supplier for your exact requirements
. The appropriate line size from the following table is then
installed from the low pressure regulator to the generator
set.
Feet* Size of pipe
Up to 25 ft 1.25” pipe
Over 25 ft Use a two regulator system
*Allow an additional 3 feet for each standard elbow.
DO NOT use ‘street ells’ (restrictive).

8
OPM-124/B
LP TANK SIZING
Tank Temperature Tank Size
60° F (16° C) 1,000 Gallons
32° F (0° C) 2,000 Gallons
0° F (18° C)* 5,000 Gallons
-20° F (-29° C)* 10,000 Gallons
* Liquid withdrawal is recommended at these temperatures.
LIQUID WITHDRAWAL SYSTEMS
When installing a unit equipped with the LP liquid
withdrawal, a primary regulator is not required on the
supply tank. The supply line is connected to a liquid
withdrawal valve on the supply tank and runs directly to
the fuellock strainer mounted on the engine generator
set. Normally a 3/8 to 1/2 inch copper line is acceptable
for this type of fuel installation. You must be sure that the
valve you have connected to on the supply tank is in fact a
liquid supply valve and has a drop tube inside the tank that
is pulling fuel from the bottom of the supply tank. Before
starting the unit, you must confirm that you have a good
liquid supply at the unit. Engine generator sets equipped
for liquid withdrawal will not run properly when
supplied with vapor fuel.
NATURAL GAS (NG)
The primary regulator (fuel meter) on the building should
deliver the correct volume and pressure to the generator
set. This regulator must be sized to deliver the required
BTU’s to the generator set and all other appliances in the
building. If the primary regulator (fuel meter) is a high
pressure regulator, then a low pressure regulator must be
installed to bring the pressure down to 4-6 oz. (7-11 inches
water column) of pressure. This low pressure regulator must
be at least 10 feet from the engine generator set; any closer
installation will require a larger line be installed to provide
a fuel reservoir. If this is not done, the demand regulator
on the unit and the pressure regulator in the fuel line will
interfere with each other. This regulator must be sized to
accommodate the demand of the generator set and any
other appliance connected to it. See the following table for
the correct size of pipe to be installed.
Feet* Size of pipe
Up to 25 ft 1.25” pipe
Over 25 ft** Use a two regulator system
*Allow an additional 3 feet for each standard elbow.
DO NOT use ‘street ells’ (restrictive).
WARNING: PERSONAL DANGER
Do not use galvanized pipe in fuel line runs. The
galvanized coating can become eroded and flake off,
causing possible obstructions in the regulator or fuel
valve. The results could range from inoperative engine
to hazardous fuel leaks.
CAUTION
Be careful when sealing gas joints. Excessive sealing
compound can be drawn into the solenoid, regulator or
carburetor causing an engine malfunction.
FUEL PRESSURE
Correct fuel pressure cannot be stressed enough. The most
common cause for inoperative systems is an inadequate
or incorrect fuel pressure. Performance of the engine is in
direct relation to the correctness of the fuel system. Shown
below is a diagram of a typical LP vapor fuel installation.
Notice the following tables give two different units of
measuring fuel pressure. The first and most accurate is
the use of a simple water manometer. A manometer is
calibrated in inches of water column . The second is with a
pressure gauge calibrated in ounces per square inch.
Reference numbers 1 through 3 in the diagram above are
system parts supplied by the customer. Reference number 4
is on the generator.
The following diagram is of a natural gas (NG) installation.
Reference numbers 2 through 4 in the previous diagram
are system parts supplied by the customer. Reference
number 4 is on the generator.

9OPM-124/B
FUEL PRESSURE TABLES
The following tables are the fuel pressure readings at each
reference in the system.
Single low pressure regulator (LP vapor only)
Ref# 134
Unit off Line PSI 7-11 in
4-6 oz
7-11 in
4-6 oz
Starting Line PSI 7-11 in
4-6 oz
7-11 in
4-6 oz
No load Line PSI 7-11 in
4-6 oz
7-11 in
4-6 oz
Full load Line PSI 7-11 in
4-6 oz
7-11 in
4-6 oz
Two regulator system (LP vapor only)
Ref# 1 2 3 4
Unit off Line PSI 10-15 lbs 7-11 in
4-6 oz
7-11 in
4-6 oz
Starting Line PSI 10-15 lbs 7-11 in
4-6 oz
7-11 in
4-6 oz
No load Line PSI 10-15 lbs 7-11 in
4-6 oz
7-11 in
4-6 oz
Full load Line PSI 10-15 lbs 7-11 in
4-6 oz
7-11 in
4-6 oz
Natural gas
Ref# 234
Unit off 2 PSI 7-11 in
4-6 oz
7-11 in
4-6 oz
Starting 2 PSI 7-11 in
4-6 oz
7-11 in
4-6 oz
No load 2 PSI 7-11 in
4-6 oz
7-11 in
4-6 oz
Full load 2 PSI 7-11 in
4-6 oz
7-11 in
4-6 oz
NG/LP FUEL CONVERSION
This generator set was tested on both LP and NG at the
factory. Ensure proper fuel configuration before operating.
CAUTION: EQUIPMENT DAMAGE
Do not make any fuel adjustments or governor
adjustments until all pressure readings are in
compliance with specification.
These engine/generator sets are easy to convert between LP
or NG. As the engine timing is controlled by the ECU on the
engine you only need to tell it what fuel you want to operate
on. A small rocker switch has been provide on the underside
of the engine control cabinet for this purpose.
Opening the rocker switch will tell the ECU mounted on the
engine that you are operating on NG Fuel. Closing the rocker
switch will tell the ECU that the fuel being supplied is LP. The
Advance Power Controller has an indicator light for LP. When
this light is on, the engine is set-up for LP, when the LP light is
out the engine is set up for NG. The ECU will then reprogram
the engine to operate on the proper fuel.
LUBRICATION & COOLANT
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 do so will cause excessive engine wear and shorten
its useful life.
Winco recommends our 5W-30 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.
Before starting the engine, Check the coolant level in
the radiator. If it is low, refill as specified in the engine
manufacturer’s maintenance instructions. The radiator should
be filled to about 1 inch below the filler neck.

10
OPM-124/B
INSTALLING THE BATTERY
CAUTION
In the following battery installation procedure, check to
be sure the selector switch remains in the ‘off’ position.
This should be your last step before initial start-up.
A customer supplied twelve-volt battery is required to
complete the
installation. Installation of the highest CCA rated battery,
within the
correct BCI group (size), will increase cold weather starting
performance. Gel batteries should not be used with the
battery tender installed in the generator enclosure.
Voltage BCI Group MIN. CCA Rating
12 31 900
Installation and servicing of batteries must be performed
or supervised only by persons knowledgeable of batteries
and the required precautions. Keep unauthorized persons
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 of 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 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
and damage electronic components.
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 and disconnect the negative
cable first and then the positive cable.
5. Be sure all connections are tight and coat the
terminals and cable ends with dielectric grease.
WARNING
The electrolyte is a diluted sulfuric acid that is harmful
to the skin and eyes. It is electrically conductive and
corrosive, The following precautions must always be
taken.
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 immediately and
thoroughly with water. 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 biocarbonate of soda (baking
soda) to one gallon of water. The biocarbonate of soda
is to be added until the evidence of reaction, foaming,
has ceased the resulting liquid is to be flushed with
water and the area dried.
DANGER: EXPLOSIVE FIRE RISK
Never smoke near batteries.
Do not cause a flame or spark in the battery area.
Always discharge static electricity from your body
before touching batteries by first touching a 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. When refilling the battery with
water, use only distilled water. Tap water will shorten the
service life of the battery.
Never fill the battery above the fill line. Over filling above
the upper level line may cause electrolyte to overflow,
resulting in corrosion to the engine or nearby parts.
Immediately wash off any spilled electrolyte following the
procedure above.
BATTERY CHARGING
This generator is equipped with an engine mounted
alternator that will recharge the battery during operation.
It is not necessary to have the battery charger circuit on the
emergency distribution circuit.
CAUTION: EQUIPMENT DAMAGE
Always connect the positive cable first and the negative
cable last. When disconnecting, remove the negative
cable first and the positive cable last. Failure to connect
and disconnect in the proper sequence can cause
equipment damage.
Observe polarities: connect the positive (+) battery
terminal to the (+) cable from the engine starter; the
negative (-) battery terminal is connected to the negative
cable (ground) from the engine generator assembly. All
connections must be clean and tight. Check the electrolyte
(fluid) in the battery periodically to be sure it is above the
plates. Never allow the battery to remain in a discharge
condition.

11 OPM-124/B
CAUTION: EQUIPMENT DAMAGE
NEVER JUMP START these units. Doing so will destroy
the engine control module, rendering the unit non-
operational. Remove and fully recharge the battery
before attempting to start.
CONNECTING BATTERY CHARGER &
BLOCK HEATER
A three-stage battery charger is provided standard for all 12
volt standby systems. The standard charger is an Automatic
Battery Charger & Maintainer. This Charger has three rates
of charging. During the first stage, know as BULK Charging,
the charging current is limited to 2 Amps at a voltage of
up to 14.5 volts. The green LED will blink during this stage.
During stage two, know as ABSORPTION Charging, the
charging voltage is held at 14.5 volts and the charging rate
gradually reduces the amount of current (amps) flowing to
the battery. The green LED will also blink during this stage.
Stage three is called MAINTENANCE Charging. During this
stage the voltage will drop to 13.3 volts and the charge
rate will drop to as low at .1 amps. This keeps your batteries
in a fully charged condition without over charging them.
During this stage the green LED is constantly lit. There are
optional 5 and 10 amp chargers available that may be
installed on some units
The block heater is thermostatically controlled and when
plugged in will maintain the engine coolant temperature
between 100 and 120 degrees F.
NOTICE
The trickle charger is not intended to recharge a battery
which has become completely discharged. It is designed
to produce just enough current to maintain a fully
charged battery.
The battery tender and block heater are powered by a
customer supplied GFCI circuit and installed in accordance
with the United States National Electric Code. These AC
wires can be run in the same conduit as the other AC leads
from the generator. It is suggested that this circuit be fused
for 20 amps when the block heater and battery charger are
on shared circuits and two 15 amp circuits when they are
split. Splitting the battery charger and block heaters circuits
are advantageous that if one of the components fail in a
manner causing the breaker to trip the other component
will be unaffected and continue operating normally.
The block heater and battery charger are both hard wired
into a terminal block located in the AC wiring cabinet.

12
OPM-124/B
AC CONNECTIONS
NOTICE:
CLASS 1 WIRING METHODS ARE TO BE USED FOR ALL
FIELD WIRING CONNECTIONS TO TERMINAL OF A CLASS
2 CIRCUIT.
WARNING
A mainline circuit breaker has been provided inside the
generator housing. During all wiring installation, make
sure the breaker is in the off position and the generator
operators switch is in the off position.
A - Neutral Lugs, These neutral lugs are isolated from
ground and provided for you to connect your neutral wire
from the transfer switch. The lugs will handle wire sizes #1
AWG TO 300 MCM and should be torqued to 250 in. lbs.
B - 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 on
the 60kW will accommodate #1 AWG to 250 MCM and
should be torqued to 250 in. lbs. The lugs on the 90kW
will accommodate #1 AWG to 300 MCM and should be
torqued to 250 in. lbs.
C. 120 Volt Terminal Block. These terminals are for shore
power. For a power line with one lead, plug into either
terminals, ensuring the jumper is still connected. To isolate
two leads for use of two separate circuit breakers, the
jumper must be removed.
D.
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.
Your generator is equipped with an electronic circuit
breaker. These premium circuit breakers are adjustable
allowing you to fine tune them for your applications.
WINCO uses an adjustable breaker, which allows us to
use the same breakers in reconnectable units. These
adjustment should only be made by a competent
technician to prevent equipment damage, injury or
death. The following features are adjustable:
Long-Time Protection:
The dial that controls the long-time protection is labeled
Ir. The dial correlates with the amperage setting of the
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A
D
B
C
CB PANEL
long-trip. All the wires should be sized equal to or greater
than this dial position. The breaker will not trip at 105% of
the dial position current and will trip within two hours of
120% of the dial position.
Short Time Protection:
The dial that controls the short-time protection is labeled
Isd (x In). This setting controls the inrush current the
circuit breaker will allow. The number on the dial is the
current allowable based upon the long-time (Ir) setting
of the breakers. For example, if the Irof the breaker is set
at 200 and the Isd is set at 1.5 the short term breaker
setting is 250 amps.
Instantaneous Protection:
The dial that controls the instantaneous protection is
labeled Ii (x In). The breaker will trip immediately upon
reaching this current level. The dial is set as a multiple of
the Long-time (Ir) setting.
The circuit breaker has three LED lights on it.
Ready LED (green)
Blinks slowly when the electronic trip unit is ready to
provide protection.
Overload Pre-Alarm LED (orange)
Shows a steady light when the load exceeds 90% of the Ir
setting.
Overload Alarm LED (red)
Shows a steady light when the load exceeds 105% of the
Irsetting.
GROUNDING
A grounding lug has been provided on the engine
generator set. Check your local codes for proper grounding
requirements.
MOUNTING THE ATS
See the ASCO installation manual for additional details on
proper wiring of the Automatic Transfer Switch.
Because of the 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 A.T.S. Control and safety systems will eliminate all
paths for feedback.
To wire the automatic transfer switch into the existing
wiring, first determine which circuits will be on the
emergency load circuit. If the entire load is to be transferred,

13 OPM-124/B
the transfer switch can be wired in 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 A.T.S. 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.
WARNING
A service disconnect must be installed in front of the
ATS panel as the ATS is not service entrance rated. This
will allow you to test the generator under load. Should
you ever have to work on the switch, you will be able
to disconnect the power and work on the switch cold
without having the power company pull your meter.
To wire the automatic transfer switch into the existing
wiring, first determine which circuits will be on the
emergency load circuit. If the entire load is to be transferred,
the transfer switch can be wired in directly after the watt-
hour meter and the service 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 reinstalled in 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.

14
OPM-124/B
DC CONNECTION
CAUTION
Never run the AC and DC wiring on the same conduit.
NOTE
There are various DC connectors on the engine that
have nothing connected to them. This was done
intentionally, the connectors are for END OF THE LINE
TESTING and other diagnostic tests. They are not used
during normal operations and can just be ignored.
All DC connections are completed on the terminal strip just
below the engine control cabinet.
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
and 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 MKII
controller.
D
C
B
A
E
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 ATS
Two control wires are required between the ATS panel
and the generator control terminal box. Depending on the
distance, 14 and 16 gauge stranded wire should be used.
These wires should be labeled S1 and S23.
WARNING:
Be sure engine generator is in the OFF position before you
make any DC interconnections.
ASCO 300 UL SWITCH
When Normal
Source Fails
Terminals On
Transfer Switch
Contact Closes TB1 and TB2
Contact Opens TB1 and TB3
Engine start and auxiliary circuit terminal block TB located
on 3ATS &3NTS transfer switch.

15 OPM-124/B
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, deactivates 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.
A small rocker switch is located on the
underside of the engine control cabinet.
On gaseous models, the engine timing is
controlled by the ECU on the engine and you
need to tell it what fuel you want to operate
on; LP or NG.
On diesel models, this switch has been
disconnected and will do nothing.
PROTECTIONS
When an alarm is present, the common alarm LED if
configures 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 flashing in the display.
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
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 DSE7310 will start the cranking cycle (10
seconds on and 10 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. 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).
If you have the proper voltage at the generator the next

16
OPM-124/B
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.

17 OPM-124/B
AVR 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.
1. VOLTS - Adjust generator output voltage.
Clockwise to increase voltage.
2. LINK: HAND TRIMMER
1-2: NO TRIMMER
NONE: TRIMMER FITTED
Adjust alternator output voltage.
Clockwise to increase voltage by AVR voltage adjustment.
3. STABILITY - To prevent voltage hunting.
Clockwise to increase dampening effect.
4. LINK: POWER: RESPONSE
A-B: > 550kW : Fast
B-C: 100-550kW : Fast
A-C: < 100kW : Fast
B-D: < 100kW : Slow
5. UFRO - Under Frequency Roll Off
Clockwise decreases ‘KNEE’ point.
6. SWITCH - Select alternator frequency for UFRO
SWITCH LEFT: 60Hz
SWITCH RIGHT: 50Hz
7. LED Indicator Light - LED light on in UFRO or O/EXC
condition.
8. DROOP - Adjust alternator droop to 5% at zero power
factor.
Clockwise to increase droop.
9. TRIM - Adjust analog input sensitivity.
Clockwise to increase sensitivity.
10. O/EXC - Adjust over-excitation trip.
Clockwise to increase trip voltage.
11. LINK: SUPPLY
8-Z2: Main stator
None: Auxiliary winding
Select AVR supply source.
1
9
10
11
2
7
643
8
5

18
OPM-124/B
TROUBLE SHOOTING TABLES
UNIT WILL NOT
CRANK WHEN THE
POWER FAILS
1. Digital genset controller not in “AUTO”
2. Transfer control switch not in “AUTOMATIC”.
3. Incorrect wiring between transfer switch and generator.
4. Loose or dirty battery terminals.
5. Defective engine control module.
6. Defective starter.
7. Defective start solenoid.
8. Defective start/stop control in the transfer switch.
9. ATS panel in fault from previous run cycle.
10. Blown fuse on generator control panel.
ENGINE WILL NOT
CRANK USING START
BUTTON ON THE
GENERATOR
1. Low or dead battery, must hold 12
Volts during cranking.
2. Blown fuse on generator control panel.
3. Loose or dirty battery terminals.
4. Defective engine control module.
5. Defective starter.
6. Defective start solenoid.
7. Locked up engine generator set.
ENGINE CRANKS BUT
WILL NOT START
1. Improper fuel pressure being delivered to unit.
2. Fuel supply shut-off.
3. Fuel supply empty.
4. Defective spark plug.
5. Defective engine ignition module.
6. Dirty air cleaner filter
7. Defective fuel solenoid valve.
8. Low Voltage from battery to fuel solenoid, must hold 12 Volts during cranking.
9. Defective fuel regulator.
10. Defective starter/fuel solenoid relay(s).
ENGINE START AND
THEN STOPS -
Alarm light comes on
1. Engine is low on oil
2. Engine has high water temperature.
3. Engine has overspeed.
4. Engine has gone into overcrank.
5. No output from engine alternator to engage stop crank cycle.
6. Generator is not operating at the correct speed.
7. Defective ECU on the engine.
ENGINE WILL NOT
COME UP TO SPEED
AFTER IT STARTS
1. Insufficient fuel volume getting to the unit.
a. Fuel line too small.
b. Low fuel pressure.
2. AC short circuit.
3. Defective ECU on the engine.
4. Governor is defective.
ATS PANEL WILL
NOT TRANSFER TO
EMERGENCY SUPPLY
1. No AC generator out put from generator.
2. See Automatic Transfer Switch Manual.
ATS PANEL WILL NOT
PULL IN ON NORMAL
POWER
1. See Automatic Transfer Switch Manual.
NO AC OUTPUT FROM
GENERATOR
1. Defective diodes.
2. Defective voltage regulator.
3. Defective rotor.
4. Defective stator.
5. Defective exciter rotor.
6. Defective exciter stator.
7. AC short in the input leads.
8. Defective/Open breaker.
9. Wiring error.

19 OPM-124/B
MAINTENANCE
MAINTENANCE SCHEDULE
SERVICE INTERVALS
Check Engine Oil Level Daily
Check Coolant Level and for Leakage Daily
Change Engine Oil and Filter Every 250 hrs
Check LPG System for Leaks Prior to Service
Inspect Accessory Drive Belt for Cracks, Breaks, Splits,
Glazing
Every 250 Hrs
Clean Debris From Radiator Core Every 250 hrs
Inspect Coolant Every 250 Hrs
Inspect Spark Plugs Every 1000 Hrs
Inspect Distributor Cap and Rotor Every 1000 Hrs
Inspect Spark Plug Wires Every 1000 Hrs
Inspect Air Filter Every 500 Hrs
Replace Air Filter Every 1000 Hrs
Inspect Lock-Off Valves Every 1000 Hrs
Check Fuel Lines for Leaks Every 250 Hrs
Inspect Oxygen Sensor Every 1000 Hrs
Inspect PCV System Every 1000 Hrs
* There are additional maintenance items and explanations
in the engine operator’s manual. Read thoroughly before
operating this unit.
PREVENTATIVE MAINTENANCE
Reasonable care in preventative maintenance will ensure
high reliability and a long life for the engine-generator set
and Automatic Transfer Switch.
WARNING
When performing any type of maintenance on this
equipment, make sure the selector switch on the
engine-generator is in the off position. If you are
working in the Automatic Transfer Switch, confirm with
a reliable meter that all power has been disconnected.
AUTOMATIC TRANSFER SWITCH
Clean and inspect the switch once a year. De-energize
all power sources, both line and engine-generator set,
then brush and vacuum away any excessive dust or
dirt accumulation. At this time, with the conductor de-
energized, you can remove the contact covers and check
the contacts. Make sure contacts are clean and not burned
or pitted.
ENGINE-GENERATOR SET
Service the engine in accordance with the engine
manufacturer’s manual provided with your new equipment.
Routinely remove debris and dirt from around the inside
generator enclosure. Ensure that the air intakes are free
from leaves and other debris at all times.
Clean and inspect battery terminals at least twice a year.
Also check the battery water level at least twice a year.
Other than keeping the generator clean and free of debris,
there is no other routine or preventative maintenance
required as long as the generator is run bi-weekly to keep it
dry and in good working order.
COLD WEATHER OPERATION
Extreme cold weather operation requires special
considerations. Higher CCA batteries are required for cold
weather starting; 650 CCA or larger are recommended. In
addition, you should consider installing an oil heater kit and
a battery warmer for reliable starting during cold weather.
WARNING
Never jump start these units. Jump starting these units
with low or bad batteries will cause permanent damage
to the engine control module.

20
OPM-124/B
AC WIRING
24 5060-0060708-165
THREE PHASE AC WIRING
HIGH AND LOW WYE
THREE PHASE-LOW WYE
120/208 VOLTS
THREE PHASE-HIGH WYE
277/480 VOLTS
24 5060-0060708-165
THREE PHASE AC WIRING
HIGH AND LOW WYE
THREE PHASE-LOW WYE
120/208 VOLTS
THREE PHASE-HIGH WYE
277/480 VOLTS
3-PH HIGH WYE 277/480V
3-PH LOW WYE120/208V