Operators Manual
Contents
1. Receptacles G3 Hot TYPICAL 4000 WATT GENERATOR The following currents measured in amps are produced at 120 amp 240 volts for typical wattage shown AMPSAT 120 VOLT 240 VOLT RECEPTACLEID MODEL A C B TB1500C 12 5 N A N A TB2400C 20 N A N A TB4000C 16 7 16 7 16 7 TB4000 16 7 16 7 16 7 TB6000C 25 25 25 TB6000 25 25 25 TB7200 30 30 30 Customer connections are made on the back side of the circuit breaker This unit has a junction box rather than recep tacles Ref a is the G1 lead Ref c is the G3 lead and Ref b is G1 to G3 rating 2 Starting Electric Motors Electric motors require much Page 2 more current amps to start them than to run them Some motors particularly low cost split phase motors are very hard to start and require 5 to 7 times as much currentto start them as to run them Capacitor motors are easier to start and usually require 2 to 4 times as much current to start them as to run them Repulsion Induction motors are the easiest to start and usually require 1 1 2 to 2 1 2 times as much to start them as to run them Most fractional horsepower motors take about the same amount of current to run them whether they are of Repul sion Induction RI Capacitor Cap or Split Phase SP type The chart below shows the approximate current required to start and run various types of sizes of 120 volt 60 cycle electric motors under average load conditions 60706 098 BASIC IN2. PLAN THE INSTALLATION Plans for installation should be prepared with proper attention to mechanical and electrical engineering detail to assure a satisfactory system installation The information in this manual is offered as a guide to finalizing your installation plans The installation sequence is summarized below Generally these two bearing generators are used on portable equipment For best service consider the following All electrical equipment should be protected from excessive moisture Failure to do so will result in deterioration of the insulation and will result in short circuits and grounds 2 The generator should be installed in a sheltered area If the unit must be left in the open it should always be protected with a weather cover such as a tarp or large piece of canvas after each use to keep out water and dust 60706 098 BASIC OPERATION CAUTION Always allow the generator and prime mover to cool before covering with a flammable weather covering CAUTION The generator must be mounted with the engine to a common rigid base to prevent stress on the engine and generator shafts and bearings due to vibration displacement For permanent installations the engine generator is usually mounted on a sub frame which can be shock mounted with special neoprene pads on the main frame CONNECTING THE LOADS 1 Applying The Load A short warm up time will permit the engine to work
3. ROTOR INCO ING A Division of DTWe Dyna Technology Ine 225 South Cordova Avenue Le Center Minnesota 56057 60706 098 21610
4. WINES ING voe A Division of DTE Dyna Technology Inc GENERATORS INSTALLATION OPERATION and MAINTENANCE INSTRUC TIONS TB4000 TB1500C OWNERS MANUAL TB6000 TB2400C TB7200 TB4000C TB6000C TB2400 TB4000 TB6000 TB7200 INGO ING 60706 098 A Division of DT Dyna Technology ne Read and understand all instructions in the manual before starting and operating the generator set USING THIS MANUAL Congratulations on your choice of a Winco generator set You have selected a high quality precision engi neered generator set designed and tested to give you years of satisfactory portable service To get the best performance from your new engine generator set it is important that you carefully read and follow the operating instructions in this manual Should you experience a problem please follow the Things To Check near the end of this manual The warranty listed in this manual describes what you can expect from WINCO should you need service assistance in the future TABLE OF CONTENTS PROPER USE AND INSTALLATION You must be sure your new generator set is Properly serviced before starting Wired by a qualified electrician Operated only for its designed purposes Used only by operators who understand its operation Properly maintained COPY YOUR MODEL AND SERIAL NUMBER HERE No other WINCO generator has the same serial number as yours Itis important that you record the number and other vita
5. 1 2 hp TB2400 3 4 hp TB4000 1 1 2 hp TB6000 3 hp TB7200 5 hp Trying to start a larger motor or higher code ie J or K motormay resultin damageto boththe generatorand the electric motor especially 120 volt motors UNPACKING INSTRUCTIONS NOTICE When unpacking the generator be sure to inspect it carefully for freight loss or damage If loss or damage is noted at the time of delivery require that the person making the delivery make a note of the loss or damage on the freight bill or affix his signature under the consigner s memo of the loss or damage Contact the carrier for claim procedures When loss or damage is noted after delivery segre gate the damaged material and contact the carrier for claim procedures CONCEALED DAMAGE is understood to mean damage to the contents of a package which is not in evidence at the time of delivery by the carrier but which is discovered later The carrier or carriers are respon sible for merchandise lost or damaged in transit The title to goods rests with the consignee when genera tors are shipped fob factory and only the consignee can legally file claims 1 Carefully open carton 2 After inspecting the generator for external physical damage check for the owner s manual operating instructions wiring diagram parts list inside the carton 2 Remove generator hold down bolts 4 Unit can now be lifted from shipping base kkk CAUTION kkkk Before proceeding
6. more efficiently when the load is applied and will reduce the wear and extend its life a Receptacles have been provided on the control panel toconnectthe loads on the models TB1500C TB2400C TB4000C TB6000C Onthe models TB2400 TB4000 TB6000 the connections are made on the back side of the circuit breakers The TB7200 has a junction box mounted on the top of the generator The loads should be applied gradually If a large motor is being started or multiple motors are being started they should be started individually and the largest should be started first CAUTION EQUIPMENT OVERLOAD Keep the generator load within the generator and receptacle nameplate rating Over loading may cause damage to the generator and or the loads b Most electric tools and appliances will have the voltage and amperage requirements on their individual name plates When in doubt consult the manufacturer or a local electrician The nameplate amperage rating for electric motors can be misleading See Starting Elec tric Motors in Specification Section c These engine generator sets are inherently self regu lating based on engine speed The engine governor will automatically adjust itself to the load No harm to the generator will result if it is operated with no load connected d Proper utilization amperage is necessary to prevent damage to either the receptacles breakers or the gen erator The generator is a limited source of electrical
7. of possible explosion and or fire a Do not refuel when the engine is running or hot Allow the engine to cool at least two minutes before refueling 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 appro priate e Store fuel only in an approved container and only ina well ventilated area 3 DEADLY EXHAUST GAS Exhaustfumes from any gaso line engine contain carbonmonoxide aninvisible odor less and deadly gas that must be mixed with fresh air a Operate only in well ventilated areas b Never operate indoors 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 or floors 4 NOISE HAZARD Excessive noise is not only tiring but continual exposure can lead to loss of hearing a Use hearing protection equipment when working around this equipment for long periods of time b Keep your neighbors in mind when permanently in stalling 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 material that could create potential fire hazards c Carefully wipe up any gas or oil spills before starting the unit d Never allow leaves o
8. power therefore pay special attention to the receptacle and generator ratings The nameplate rating can be obtained through a 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 Specification Section for proper load separation e Plug your tools such as drills saws blowers sump 60706 098 Page 5 pump and other items to be powered directly into the generator receptacles Before plugging in all the tools and cord sets recheck the rating of the generator set Be sure it can handle the intended load and is compatible with the voltage phase and current ratings f Hard Wiring this unit directly into a temporary construc tion site electrical system is NOT A SIMPLE DO IT YOURSELF JOB For your safety all wiring must be done by a qualified electrician and conform to the National Electric Code and comply with all state and local codes and regulations Check with local authori ties before proceeding WARNING PERSONAL DANGER A fully isolated double pole double 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 bal ance the load applied to the generator will cause the generator to produce low voltage and may damage the engine generator set It may also cause
9. severe damage to the loads connected to the generator at that time Improper loading of the generator set constitutes abuse and will not be covered by warranty COMMON PROBLEMS Sometimes problems can be easily solved by checking a few basic things Check below before you call or take your unit to a service center It could save you time and money Voltage too low Engine speed is too low Generator overloaded Defective stator Defective rotor field Circuit Breaker Trips Defective load Defective receptacle Voltage too high Engine speed is too high Generatoroverheating Overloaded Insufficient ventilation Nooutputvoltage Short in load disconnect Broken or loose wire Defective receptacle Defective capacitor Defective diode No residual magnetism in generator Defective stator Defective rotor field TB SERIES WIRING DIAGRAMS EXCITATION WINDING CIRCUIT STATOR BREAKERS CAPACITOR TB1500C TB2400C WINDING STATOR UNMARKED LEADS EXCITATION FIELD RECTIFIERS COILS ROTOR GROUND EXCITATION WINDING STATOR CIRCUIT BREAKER RECEPTACLES TB4000C TB6000C EXCITATION RECTIFIERS fo WINDING LEADS lt FIELD COILS ROTOR CIRCUIT BREAKER A C OUTPUT WINDING 120 VOLTS EXCITATION WINDING STATOR TB4000 TB6000 TB7200 VOLTS CAPACITOR EXCITATION RECTIFIERS UD rasp COILS
10. with the installation be sure that you have completely read and understand the assembly and installation instructions ASSEMBLY 1 An engine with adequate horsepower and a close Page 3 regulating fixed speed governor is required for satisfactory operation of any alternating current generator TB SERIES INSTALLATION These units require approximately two 2 horsepower for every 1000 watts of generator output Theoretically you should be able to produce 1000 watts with 1 4 Horsepower but this is only possible with 100 efficiencies in both the engine and the generator Between engine and generator efficiencies of only 80 to 90 and the losses through the drive system the two horsepower requirement is more realistic For example this 1 500 watt generator output will require a 3 or 4 h p Engine for full output good speed voltage regulation and satisfactory load performance 2 When determining the prime mover generator pulley ratio to drive the generator at the correct operating speed bear in mind that the power rating of most prime movers usually an engine varies with the speed that is it produces more power at higher speeds less when slowed The prime mover must be run fast enough to reach the desired horsepower for good generator set 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 overtighten to the extent th
11. AAI AS ASIA AIA AIA AAAI AAIAAAAAAAAA AE doicintniciootetiteioioicioteieinicieinieieieinininininininicinicinieininieiniieinioieiiekiciokeiokcdeddeddedee WARNING WARNING indicates a potentially hazard oussituation which if notavoided could result in death or serious injury RIAA IAI IIIA IRI IAAI III IIIA III IIIA IIIS SII AI IAI IIIS IA RIAA IR III IIR III RIS III III I IIIS IIIA IIIA CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may re sult in minor or moderate injury It may also be used to alert against unsafe practices PRAIA AIRS III III III IAI IIIS IA IIIS IIIS II ASIII IIA NOTE CAUTION is also used on the unitlabels and in this manual to indicatea situation that could result in serious damage or de struction of the equipmentand possible personal injury 1 ELECTRIC SHOCK The output voltage presentin this equipmentcan causea fatal electric shock This equip ment 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 receptacles and exten sion cords f Be sure the unit is properly grounded to an external ground rod driven into the earth 60706 098 Page 1 2 FIREHAZARD Gasoline and otherfuels always present a hazard
12. FORMATION RUNNING STARTINGAMPS HP AMPS SP CAP RI 1 6 3 2 16 TO 22 6TO13 5TO 8 1 4 4 5 22 TO 32 9T018 7TO12 1 3 5 2 26 TO 35 10 TO2 18TO 17 1 2 7 2 NOTMADE 14 TO 29 11TO18 1 13 0 NOTMADE 26 TO 52 20 TO 33 The figures 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 For 240 volt motors the running current is half as much as shown for the 120 volt motors of the same size Some dual voltage 120 240 volt motors are difficult to start on 240 volts when driven by engine generators and can be started more easily when connected to operate on 120 volts This is particularly true of capacitor start induction run motors Sometimes a 240 volt motor which cannot be started on the 240 voltcircuit ofa 120 240 volt generator can be started on a 120 volt circuit and then quickly switched to the 240 volt circuit after it is started This can be done in applications where the motor is manually controlled and is started under no load conditions A self excited generator responds differently to severe overloading than the power line To illustrate suppose that a 240 volt 10 H P capacitor start Induction Run motor is connected to the g
13. at 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 pullies will cause excessive belt and pulley wear and unnecessary stress on the prime mover 3 The following table shows the effect of various operating speeds and electrical loads on a typical generator when matched and mounted to an adequate prime mover Although individual units and models may vary slightly the normal voltage and frequency of typical 60 cycle generators described in this book are approximately as follows when powered by a typical prime mover engine run first with no load applied then at half the generator capacity and finally when loaded to its full capacity as rated on the nameplate GENERATOR LOAD SPEED FREQUENCY VOLTAGE NONE 3690RPM 611 2HZ 129VOLTS HALF 3600 RPM 60 HZ 120 VOLTS FULL 3510RPM 581 2HZ 115VOLTS kkk CAUTION ke Required generator speed must be maintained at 3600 90 rpm under all load conditions 4 All engines have a tendency to slow down when a load is applied The governor on the engine is designed to hold the 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 TB SERIES Page 4 together with the natural voltage drop within
14. conditions specified by the prime mover manufacturer INTRODUCTION AND DESCRIPTION The generator is a 3600 rpm two bearing belt driven brushless revolving field 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 dam aged The frequency regulation is determined by the sensitivity of the customer supplied prime movers 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 Generator Specifications MODEL WATTS VOLTS AMPS HZ PH RPM TB1500C 2000 120 16 60 1 3600 TB2400C 2400 120 20 60 1 3600 TB4000 4000 120 240 33 16 60 1 3600 TB4000C 4000 120 240 33 16 60 1 3600 TB6000 6000 120 240 50 25 60 1 3600 TB6000C 6000 120 240 50 25 60 1 3600 TB7200 7200 120 240 60 30 60 1 3600 UNIT CAPABILITIES 1 Generator Connections The diagram below represents atypical ordinary 4000 watt generator Only 2000 watts at 120 volts 16 7 Amps can be taken from the generator at receptacle A and up to 2000 watts at 120 volts from receptacle C Onan ordinary generator CAUTION MUST BE EXERCISED TO PREVENT OVERLOADING EITHER OF THE 120 VOLT CIRCUITS A OR C TB SERIES CONVENTIONAL DUAL VOLTAGE 120 240 VOLT SCHEMATIC C1 Hot ye Suc o 240 Volts Ky o 120 Volts A o gt C Neutral SN Hu 120 Volts
15. enerator The engine would not be able to supply enough power to bring the electric motor up to operating speed The generator would re spond with high initial starting current but the engine would be very severely overloaded The speed would probably drop sharply and possibly stall the engine If allowed to operate at very low speeds the electric motor start winding would burn out in a shorttime The generator winding might also be damaged On the other hand suppose a smaller electric motor that requires just a little more output than the generator can produce is connected to it It will try to run but will not reach a high enough speed for the internal centrifugal switch to disconnect the starting winding The generator output instead of being 120 volts may drop to 70 or 80 volts RUNNING THE GENERATOR SET UN DER EITHER OF THESE CONDITIONS COULD RESULT IN DAMAGE TO THE GENERATOR STATORAS WELLAS THE MOTOR WINDING Because the heavy surge of current required for starting motors is required for only an instant the generator will not be damaged if it can bring the motor up to speed in a few seconds of time If difficulty is experienced in starting motors turn all other electrical loads off and if possible reduce the load on the electric motor 3 Motor Starting Capacity listed below you will find the motor starting capability of your engine generator set 60706 098 Generator Motor Size Model code G capacitor start TB1500
16. l information here If you should ever need to contact us on this unit it will help us to respond to your needs faster MODEL SERIAL NUMBER INTRODUCTION i 12MONTH WARRANTY i GUIDE TOPRODUCT SAFETY 1 BASICINFORMATION Specification Table Unit Capabilities Unpacking the unit INSTALLATION OPERATION Assembly Plan The Installation Connecting The Load Common Problems PURCHASE DATE DEALER OQ NN anak WINCO Inc 12 Month Limited Warranty WINCO Incorporated warrants to the original purchaser for 12 months 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 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 fitness for a particular purpose are limited to 12 months from date of purchase In no event is WINCO liable for incidenta
17. l or consequential damages Note Some states do notallow limitation on the duration of implied warranty and some states do notallowthe exclusion or limitation of incidental or consequential damages so the above limitations may not apply in every instance This warranty gives you specific 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 batteries or other component parts that are warranted by their respective manufacturers WINCO does not warrant modifications or alterations which were not made by WINCO Inc GUIDE TO PRODUCT SAFETY This engine generator set has been designed and manu factured to allow safe reliable performance Poor mainte nance improper or careless use can result in potential deadly hazards from electrical shock exhaust gas asphyxi ation 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 ANSI SAFETY DEFINITIONS DANGER DANGER indicates an imminently hazard ous situation which if not avoided will result in death or serious injury This signal word is to be limited to the most extreme situations PIRI IRDA IIIA IIIA IAAI I
18. r other flammable material to build up around the engine exhaust area 6 SERVICING EQUIPMENT All service including the in stallation 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 All belts pullies and or drive shafts must have protec tive guards and or covers permanently installed by the assembler d Never remove the protective guards cover or recep tacle panels while the engine is running e Use extreme caution when working on electrical com ponents High output voltages from this equipment can cause serious injury or death f Always avoid hot mufflers exhaust manifolds and engine parts They all can cause severe burns in stantly TB SERIES BASIC INFORMATION 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 generators is based on factory tests of typical units and is subject to and limited by the ambient operating temperature The generator will not provide full power output unless driven by a prime mover of adequate horsepower The prime mover engine or other input power source horsepower is also affected by temperature as well as a number of other factors such as fuel altitude and all other
19. 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 in 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 However timing devices and clocks will not keep perfect time unless the engine can keep the generator running at exactly 3600 rpm at all times Since this is not usually possible minor time errors in clocks occur The speed of the engine is usually adjusted so that the generator produces proper voltage 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 CAUTION 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 insure proper operation of the generating plant and appliances CAUTION xd Low voltage may damage any motors or appliances connected to it Running the generator at excessively high speeds results in too high voltage which will also damage electrical devices connected to it Excessively high speed may also cause damage to the generator stator windings
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