Winco UL2FS2MP-1 Setup guide

WINCO INC. 225 S. CORDOVA AVE. LE CENTER, MN 56057 507-357-6821
SERVICE DEPT. 507-357-6831
www.wincogen.com
INSTALLATION AND
OPERATORS
UL2FS2MP-1
2-BEARING
GENERATOR
MANUAL

2REV B
OPM-101
TABLE OF CONTENTS
SAVE THESE INSTRUCTIONS 2
INTRODUCTION 2
SPECIFICATIONS 2
SAFETY 2
IMPORTANT SAFETY INSTRUCTIONS
ANSI SAFETY DEFINITIONS
TESTING POLICY 3
UNIT CAPABILITIES 3
GENERATOR CONNECTIONS
STARTING ELECTRIC MOTORS 3
PREPARING THE UNIT 4
UNIT INSTALLATION 4
PLAN THE INSTALLATION
MOUNTING
CONNECTING THE LOADS 5
APPLYING THE LOAD
MAINTENANCE 5
GENERAL
BRUSHES
SLIP RINGS
ELECTRICAL TESTING 6
TESTING COILS FOR OPENS AND GROUNDS
TESTING ARMATURE FOR OPENS AND GROUNDS
TESTING RECTIFIERS
TROUBLESHOOTING CHART 7
WIRING SCHEMATIC 7
12 MONTH LIMITED WARRANTY 8
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 # ________________________________________
SPECIFICATIONS
Surge Watts 2,040
Continuous Watts. 2,040
Volts 120
Amps 17
Receptacles 2 x 5-15R
UL Listed UL STD 1004-1
UL STD 1004-4
CSA 22.2 NO 100-004
SAFETY
IMPORTANT SAFETY INSTRUCTIONS
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 the
generator.
This generator has been designed and manufactured to allow safe,
reliable performance. Poor maintenance or improper/careless use
can result in injury or death. Please read all safety instructions 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
manual.
INTRODUCTION
This generator is a 3600 RPM two-bearing, belt-driven, brush, rotating
armature design. The generator is self excited and inherently regulated
to +/- (plus or minus) 7% - no load to full rated load. It can be operated
under any load within its rating without being damaged. The frequency
regulation is determined by the sensitivity of the customer supplied
prime mover’s governor. It is desirable to maintain this speed to within
3 cycles variation (61.5 Hz - 58.5 Hz) no load to full rated load (3690
RPM - 3510 RPM)

3REV B OPM-101
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 be used to alert
against unsafe practices.
NOTE: CAUTION is also used on the unit labels and in this manual to
indicate a situation that could result in serious damage or destruction of
the equipment and possible personal injury.
1. ELECTRIC SHOCK -
The output voltage present in this equipment can cause a 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-prong grounded plugs and extension cords.
F. Be sure the unit is properly grounded to an external ground rod
driven into the earth.
2. FIRE HAZARD -
 A.Keepareextinguishernearbyandknowitsproperuse.Fire
extinguishers rated ABC by NFPA are appropriate.
3. 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 permanently installing this
equipment.
4. 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.
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.
5.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 fatigued.
C. Use extreme caution when working on electrical components.
High output voltages from this equipment can cause serious
injury or death.
D. Installing a generator is not a “do-it-yourself” project. Consult
  aqualied,licensedelectricianorcontractor.Theinstallation
must comply with all national, state, and local codes.
UNIT CAPABILITIES
GENERATOR CONNECTIONS
These generators are designed for 120 Volt alternating current (AC)
use only. They utilize two different means of connecting to your loads.
Some models come with two 120 Volt outlets mounted in them and
all are hard wired. Actual connections will be discussed later in this
manual.
Check the appliance or tool nameplate for the current and voltage to
ensure compatibility.
STARTING ELECTRIC MOTORS
Electric motors require much more current (Amps) to start than to run.
Some motors, particularly low-cost split-phase motors, are very hard
to start and require 5 to 7 times as much current to start them than to
run them. Capacitor motors are easier to start and usually require 2
to 4 times as much current to start them than to run them. Repulsion
Induction motors are the easiest to start and require 1 1/2 to 2 1/2
times as much current to start them than to run them.
Most fractional horsepower motors take about the same amount
of current to run them whether they are Repulsion Induction (RI),
Capacitor (C), or Split-Phase (SP) type. The chart below shows the
approximate current required to start and run various types and sizes of
120 Volt, 60 cycle electric motors under average conditions.

4REV B
OPM-101
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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.
UNIT INSTALLATION
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 as a
guidetonalizingyourinstallationplans.Theinstallationsequenceis
summarized below.
HP AMPS
RUNNING
STARTING
AMPS
SP CAP RI
1/6 3.2 16 TO 22 6 TO 13 5 TO 8
1/4 4.5 22 TO 32 9 TO 8 7 TO 12
1/3 5.2 26 TO 35 10 TO 21 8 TO 17
1/2 7.2 NOT MADE 14 TO 29 11 TO 18
1 13.0 NOT MADE 26 TO 52 20 TO 33
Theguresgivenaboveareforaverageloadsuchasablowerorfan.
If the electric motor is connected to a hard starting load such as an air
compressor, it will require more starting current. If it is connected to a
light load, or no load such as a power saw, it will require less starting
current. The exact requirement will also vary with the brand or design
of the motor.
Self- exciting generators respond to severe overloading differently
that utility power. When over loaded, the engine is not able to supply
enough power to bring electric motor up to operating speed. The
generator responds with high initial starting current, but the engine
speed drops sharply. The overload may stall the engine. If allowed to
operate at very low speeds, the electric motor starting winding will burn
out in a short time. The generator winding may also be damaged.
PLAN THE INSTALLATION
Generally, two-bearing generators are used on portable equipment. For
best service consider the following:
1. All electrical equipment should be protected from excessive moisture.
Failure to do so will result in deterioration of the insulation, short
circuits, and grounds.
2. The generator should be installed in a sheltered area. If the unit must
be left in the open, it should always be protected with a weather cover
such as a tarp or large piece of canvas after each use to keep out water
and dust.
CAUTION: EQUIPMENT DAMAGE
Always allow the generator and prime mover to cool before covering
with a ammable weather covering.
MOUNTING
CAUTION: EQUIPMENT DAMAGE
The generator must be mounted with the engine to a common rigid
base to prevent stress on the engine and generator shafts and bearings
do to vibration displacement. For permanent installations, the engine-
generator is usually mounted on a sub-frame which can be shock
mounted with neoprene pads on the main frame.
Before proceeding with installation, be sure that you have completely
read and understood the assembly and installation instructions.
Anenginewithadequatehorsepowerandacloseregulated(xed
speed) governor is required for satisfactory operation of this generator.
About 1.4 horsepower is required to produce 1,000 Watts of generator
outputpowerassuming100%efciencyofboththeengineandthe
generator.However,duetoengineandgeneratorefcienciesof80
to 90%, the loss of power due to engine driving accessories such
as cooling fans, battery charging alternators, etc. friction losses and
slippage in the drive pulleys and belts, the general conservative rule of
thumb allowing approximately two (2) horsepower for every 1,000 Watts
of generator output is much more realistic. For example, the 2,400 Watt
generator output will require a 4.8 horsepower engine for full output,
good speed/voltage regulation, and satisfactory load performance.
When determining the prime mover/generator pulley ratio to drive the
generator at the correct operating speed, bear in mind the power rating
of most prime movers (usually an engine) varies with speed. It produces
more power at higher speeds, less when slowed. The prime mover
must be fast enough to reach desired horsepower for good generator
operation.
The drive belt system must be of adequate size and must be tight
enough to power the generator without slippage. Be careful not to
over-tighten to the extent that it puts excessive strain on the bearings.
Doing so can cause bearing failure and other possible damage to the
generator.
Alignment of the generator to the prime mover is important.
Misalignment of the pulleys will cause excessive belt and pulley wear
and unnecessary stress on the prime mover.

5REV B OPM-101
The following table shows the effect of various operating speeds and
electrical loads on a typical generator when matched and mounted to
an adequate prime mover.
LOAD VS. OUTPUT
Generator
Load
Speed
(RPM)
FREQUENCY
(Hz)
Voltage
None 3690 61.5 129V
Half 3600 60.0 120V
Full 3510 58.5 115V
*Note: Required generator speed must be at 3600 +/- 90 RPM under all
load conditions.
Although individual units and models may vary slightly, the normal
voltage and frequency of typical 60 cycle engine-driven generators
described in this manual are approximately as follows when powered
byatypicalprimemover(engine)runrstwithnoloadapplied,thenat
half capacity as rated on the nameplate.
All engines have a tendency to slow down when a load is applied.
The governor on the engine is designed to hold engine speed nearly
constant. When the electrical load connected to the generator is
increased, the engine is more heavily loaded and as a result, the
speed drops slightly. This slight decrease in speed together with the
natural “voltage drop” within the generator itself due to load current and
heating of the windings, results in a slightly lower voltage than when
the generator is running idle.
The normal slight variations on speed also directly affect the frequency
of the output current. This frequency variation has no appreciable effect
in the operation of most loads (such as motors, lights, and most small
appliances).
The speed of the engine is usually adjusted so that the generator
produces proper voltage. If the adjustment is made “cold”, set the
voltage a little higher than normal since it will drop a few Volts as the
generator warms up.
NOTE: When operating continuously at full load, the generator shell
becomes very warm. It will be uncomfortable to the touch. This is
normal for any high performance inherently regulated generator. Output
voltage should be checked periodically to ensure proper operation of
the generator and appliances.
CAUTION: EQUIPMENT DAMAGE
Low voltage may damage any motors or appliances connected to it.
Running the generator at excessively high speeds result in high voltage
which will also damage electrical devices connected to it. Excessively
high speed may also cause damage to the generator armature
windings.
CONNECTING THE LOADS
APPLYING THE LOAD
Ashortwarm-uptimewillpermittheenginetoworkmoreefciently
when the load is applied and will reduce the wear and extend its life.
CAUTION: EQUIPMENT DAMAGE:
Keep the generator load within the generator and receptacle nameplate
ratings. Overloading may cause damage to the generator and/or loads.
Most electric tools and appliances will have the voltage and amperage
requirements on their individual nameplates. When in doubt, consult
the manufacturer or a local electrician. The nameplate’s amperage
rating for electric motors can be misleading. See “Starting Electric
Motors”inspecicationsection.
The generator is a limited source of electrical power, therefore
pay special attention to the receptacle and generator ratings. The
nameplate rating can be obtained through combination of receptacles
or a single receptacle as long as the receptacle amperage rating is not
exceeded. Both the 120 and 240 Volt output can be utilized at the same
time.Seespecicationsectionforproperloadseparation.Overloading
aspecicreceptacleorwindinggroupcanresultindamagetothe
equipment.
Plug your tools such as drills, saws, blowers, sump pump, and other
items to be powered directly into the generator receptacles. Before
plugging in all of the tools and cord sets, recheck the rating of the
generator. Be sure it can handle the intended load and is compatible
with voltage, phase, and current ratings.
‘Hard Wiring’ this unit directly into a temporary construction site
electrical system is NOT A SIMPLE DO-IT-YOURSELF JOB. For
yoursafety,allwiringmustbedonebyaqualiedelectricianand
conform to the National Electric Code and all state and local codes and
regulations. Check with local authorities before proceeding.
WARNING: PERSONAL DANGER
A fully isolated, double pole throw manual transfer switch must be
installed any time a generator is being connected to an existing
distribution system.
CAUTION: EQUIPMENT DAMAGE
Failure to properly limit and balance the load applied to the generator
will cause the generator to produce low voltage and may damage the
generator. It may also cause severe damage to the loads connected to
the generator at that time. Improper loading of the generator constitutes
abuse and will not be covered by warranty.
MAINTENANCE
GENERAL
Themaincomponentsofthegeneratorare:eld,frame,eldcoils,
armature, brushes, brush holder assembly, brackets, and generator
cooling fan.
BRUSHES
Under ordinary circumstances, brushes will operate for thousands of
hours without requiring replacement. They should be inspected after
therst1000hoursofoperation,andafterevery500hoursofoperation

6REV B
OPM-101
ELECTRICAL TESTING
TESTING COILS FOR OPENS AND GROUNDS
1.Disconnecteldleadsfromrectier
2.Setmulti-metertoreadinniteresistance(veryhighohms),repairor
replaceeldifitisopen.Typicalresistancefortheseeldsvariesfrom
12.8 to 14.1 ohms.
3.Leavingonemeterleadconnectedtotheeld,connecttheother
meterleadtotheeldshell.Ifmeterindicatescontinuity(anyreading
-shouldbeinniteresistance),theeldisgroundedandshouldbe
repairedorreplaced.Todeterminewhichoftheeldsisgrounded,cut
the connector between the two coils and retest to determine which coil
has the low resistance path.
TESTING ARMATURE FOR OPENS AND GROUNDS
1. Remove all brushes
2. Ground fault test. Set multi-meter to read high resistance (mega-
ohms). Holding one meter lead against a clean spot on the armature
shaft, touch the other lead to each of the slip rings (one at a time) while
observing the meter. If the meter indicates continuity (any reading lower
than one mega ohm), the armature is grounded. Dirt between the slip
rings and on the insulator surface can cause grounding. If grounding
was indicated, carefully clean all dirt off the slip rings and their
insulators and then recheck it. Replace the armature if it is grounded
and unrepairable.
3. Testing for opens. Set meter to read low resistance (Rx 1 ohms).
Holding one meter lead on the surface of slip ring #1, touch the other
lead to surface of slip ring #2 while observing the meter. Meter should
indicate continuity (low resistance 0 less than one ohm is typical). If the
meterindicatesanopencircuit(inniteresistance)partofthearmature
winding is open. This may be caused by a repairable defect in the
connection at the slip ring, however, generally an open armature will
have to be replaced.
TESTING RECTIFIERS
Theeldexcitationissuppliedthroughfullwavebridgerectier.This
typeofrectierhasfourterminals:twoACandaDCpositive(+)and
DC negative (-). Nothing is connected to the DC negative (-) in this
generator.
Arectiermaybetestedinthefollowingmanner:
1.Disconnectallleadsfromrectier.
2. Connect the red ohmmeter lead to the positive DC (+) terminal.
3. Connect the black lead to each of the AC terminals in turn. Either a
high or low resistance reading will be obtained.
4. Reverse the meter lead, (black to the DC positive (+) and red to the
AC terminals, each in turn. An opposite reading should be observed.
5. Check each terminal to the case. An open circuit (very high
resistance) reading should be observed. If a battery powered test light
is used, follow the same procedures and previously described. A good
diode element will allow current to pass to the light in the test lamp
when the leads are connected in the forward direction.
6.Iftherectierfailsanyoftheaforementionedtests,itshouldbe
considered defective and replaced.
thereafter. Remove brushes one at a time and check for length. Be
sure that each move freely in the brush holder. Brushes should be
replaced when worn down to 3/8”. Always replace brushes in complete
sets, never singularly. When replacing brushes, be careful to connect
the lead wire properly. Poor contact or “skipping” between brush
andslipringcancauseoilandgrit,int,orotherhardcontaminant
substances on the brushes, or by the brush not being properly shaped
totthesliprings.
Remedythesedefectsbycleaningtheringsandbrushesandthetting
the brushes to the slip ring curvature. Place #00 sandpaper under the
brushes with the abrasive side to the brushes, and work it back and
forth until the brushes are the same shape as the slip rings.
SLIP RINGS
The continuous copper rings located at the end of armature are the
power collector rings or ‘slip rings’. For proper generator output, the
Surfaceoftheseslipringsmusthaveahighlypolishednish.Under
sustained use, it is advisable to check and occasionally polish ring
surfaceswithacrocusclothtomaintainthenishundernormal
conditions. This should not be required more than once each thousand
hours of operation.

7REV B OPM-101
SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION
No output or low voltage. 1. Open or shorted armature.
2.Openorgroundedeldcoil(s).
3. Generator operating below correct RPM
4. Generator overloaded.
5. Short circuit in the load.
6. Loose (or broken) wires or connections in the
control box.
7.Defectiverectier.
8. Dirty slip rings.
9. Brushes binding in holders.
10. Loss of residual magnetism.
1. Replace armature.
2.Replaceeldcoil(s).
3. Generator must be operated at 3600 RPM +/- 90 RPM for
proper output voltage.
4. Reduce load to generator nameplate.
5. Disconnect the load. Check motors, appliances and load
leads for short circuits. Repair short.
6. Remove panel cover and check all wiring and connections.
Tighten and/or repair where necessary.
7.Testrectier.Replaceifdefective.
8. Clean and polish. Use 00 sandpaper and crocus cloth,
never emery paper.
9. Check brushes for swelling. Replace defective brushes.
Clean brush holders.
10. Check output voltage with sensitive meter. If very low
(i.e.1/2volt)asheldswitha12VDCbattery.
Output voltage too high. Engine speed too high. See engine manual.
Generator overheating. 1. Generator overloaded.
2. Armature rubbing pole shoes.
3. Poor ventilation.
4.Shortcircuitinelds.
5. Short turns in armature.
1. Reduce load.
2.Checkbearingcondition.Checkeldshellbearingbracket
alignment.
3. Clear inlet and outlet air vents of debris. If unit is housed,
ensure at least 2 ft. clearance on all sides and that inlet and
outlet vents are of adequate size.
4.Repairorreplace-openorshortedeldsshouldbe
replaced.Groundedeldsmayberepairedbyinsulatingat
the point where the ground occurs.
5. Replace armature.
Sparking at the brushes. 1. Generator overloaded.
2. Brushes not seated properly.
3. Slip rings rough or eccentric.
4. Brushes sticking in brush holder.
5. Brushes worn down shorter than 3/8 inch.
1. Reduce load.
2. Contour brushes (see maint.).
3. Redress slip rings (see maint.).
4. Remove brushes and inspect and correct problem.
5. Replace brush. NOTE: Always replace brushes a full set
at a time.
TROUBLESHOOTING CHART
WIRING SCHEMATIC
WITH “Q” WINDING WITHOUT “Q” WINDING

8REV B
OPM-101
WINCO INC. • 225 S. CORDOVA AVE. • LE CENTER, MN 56057 • 507-357-6821
12 MONTH LIMITED WARRANTY
WINCO,Incorporatedwarrantstotheoriginalpurchaserfor12monthsor1000hourswhicheveroccursrst,thatgoods
manufactured or supplied by it will be free from defects in workmanship and material, provided such goods are installed,
operated and maintained in accordance with WINCO written instructions.
WINCO’s sole liability, and Purchaser’s sole remedy for a failure under this warranty, shall be limited to the repair of the
product. At WINCO’s option, material found to be defective in material or workmanship under normal use and service
will be repaired or replaced. For warranty service, return the product within 12 months or 1000 hours which ever occurs
rstfromthedateofpurchase,transportationchargesprepaid,toyournearestWINCOAuthorizedServiceCenterorto
WINCO, Inc. at Le Center Minnesota.
THERE IS NO OTHER EXPRESS WARRANTY.
Totheextentpermittedbylaw,anyandallwarranties,includingthoseofmerchantabilityandtnessforaparticular
purpose,arelimitedto12monthsor1000hourswhicheveroccursrst,fromdateofpurchase.InnoeventisWINCO
liable for incidental or consequential damages.
Note: Some states do not allow limitation on the duration of implied warranty and some states do not allow the exclusion
or limitation of incidental or consequential damages, so the above limitations may not apply in every instance. This
warrantygivesyouspeciclegalrightswhichmayvaryfromstatetostate.
WINCO reserves the right to change or improve its products without incurring any obligations to make such changes or
improvement on products purchased previously.
EXCLUSIONS:
WINCO does not warrant Engines. Engines are covered exclusively by the warranties of their respective manufacturers,
see enclosed warranties.
WINCO does not warrant Component Parts that are warranted by their respective manufacturers.
WINCOdoesnotwarrantmodicationsoralterationswhichwerenotmadebyWINCO,Inc.
WINCO does not warrant products which have been subjected to misuse and/or negligence or have been involved in an
accident.
This warranty does not include travel time, mileage, or labor for removal or re-installation of WINCO product from its
application.