Winco RP50 Installation & Operator'S Manual Download

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INSTALLATION & OPERATORS

MANUAL

RP50

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MODEL __________________________________________________

SERIAL NUMBER _________________________________________

PURCHASE DATE _________________________________________

DEALER NAME ___________________________________________

DEALER PHONE # ________________________________________

www.wincogen.com

16200-021

Summary of Contents for RP50

Page 1: ...concerning this unit it will help us to respond to your needs faster MODEL __________________________________________________ SERIAL NUMBER _________________________________________ PURCHASE DATE _________________________________________ DEALER NAME ___________________________________________ DEALER PHONE ________________________________________ www wincogen com 16200 021 ...

Page 2: ...ANCE SCHEDULE TROUBLESHOOTING TABLE 24 WIRING SIZE TABLE 25 SELECTOR SWITCH WIRING DIAGRAM 26 DSE 7310 MKII WIRING DIAGRAM 28 THREE PHASE AC WIRE HIGH WYE THREE PHASE AC WIRE LOW WYE WIRING DIAGRAMS 29 THREE PHASE WIRING DELTA SINGLE PHASE AC WIRING 4 LEAD ENGINE HARNESS 30 ENGINE CODES 31 CA EMISSION STATEMENT 37 US ENVIRO WARRANTY STATEMENT 38 REVALIDATION OF WARRANTY 39 12 MONTH LIMITED WARRANT...

Page 3: ...se of the engine generator set must comply with all national state and local codes SAFETY INFORMATION This engine generator set has been designed and manufactured to allow safe reliable performance Poor maintenance improper or careless use can result in potentially deadly hazards from electrical shock exhaust gas asphyxiation or fire Please read all safety instructions carefully before installatio...

Page 4: ...s 178 148 128 64 51 Hertz 60 60 60 60 60 Engine Fluid Specifications Fuel ASTM D 975 1D or 2D EN590 or equivalent Oil Type SEE LUBRICATION SECTION Oil Capacity 10 Quarts Cooling System 50 50 mix GENERATOR END NOTE Review the Stamford Newage nameplate on your generator Some custom applications use other models Check the generator nameplate for actual model number Additional generator information av...

Page 5: ...r based electronic Engine Control Module ECM with an LCD digital display The generator set ECM control is mounted on a vertical pedestal on the right side of the generator The ECM is programmed with a cycle cranking sequence 3 cycles of 15 seconds on 15 seconds off and 5 minute cool down delay The cool down delay can be changed in the field from 0 to 30 minutes by your installer Other features tim...

Page 6: ... the equipment is kept clear 2 Be certain rigging is designed to lift unit safely 3 Never attempt to lift the unit unless you are certain the lifting device has sufficient capacity 4 Never allow the unit to swing while suspended 5 Be certain the supporting structure is adequate to handle the weight of the unit CAUTION Only lift the unit using the factory installed lifting eye located on top of the...

Page 7: ... wooden base structure Over time the wood will deteriorate and the unit mountings will come loose These units must be mounted to a steel or concrete base The unit should be mounted to allow ample working room around it A general rule to follow is to allow 24 inches or more of clearance for maintenance Follow local codes for clearance from combustible surfaces VENTILATION REQUIREMENTS OPEN SKID WAR...

Page 8: ... should be installed by a licensed fuel supplier In no case should the instructions or information provided be interpreted to conflict with any local state or national codes If in doubt always consult your local fire marshal or fuel supplier INSTALLING THE FUEL LINE WARNING FIRE DANGER Connecting rigid fuel line i e steel or copper line directly to the inlet fuel filter or fuel pump may cause the ...

Page 9: ...ew battery is fully charged before installing it on a generator set Failure to do so can cause damage to the engine control module in the generator set All connections must be clean and tight Depending on your battery type check the electrolyte in the battery periodically to be sure it is above the plates Never allow the battery to remain in a discharged condition CAUTION EQUIPMENT DAMAGE Never at...

Page 10: ... the automatic transfer switch into existing wiring first determine which circuits will be on the emergency load circuit If the entire load is transferred the transfer switch can be wired directly after the watt hour meter and the service entrance providing the service entrance ampere rating is within the transfer switch s rated capability If only specific circuits are to be powered under emergenc...

Page 11: ... position A C ELECTRICAL CONNECTIONS WARNING Wiring and connections to unit should be performed by a competent technician Improper installation could result in electrocution which could cause equipment damage serious injury or death Access for routing the wires into the terminal block is provided via the access door located in the back of the unit The top panel will hinge open once unscrewed AC CO...

Page 12: ...GE Never change the selector switch position while the engine is running The selector switch is equipped with a lockable e stop This needs to be depressed when switching voltages It is recommended that the e stop has a pad lock installed to ensure the voltage is not switched while the engine is running The three positions are 120 240V 1PH 120 208V 3PH 277 480 3PH For 120 240V 3ph place the selecto...

Page 13: ... relay is opened the unit will shut down and remain on standby mode until the remote start relay is closed again A B E STOPS In some applications additional emergency stops may be desired or necessary The controller has terminals designed allowing the addition of multiple remote emergency stops E stops must be normally closed to work properly in this system The e stop circuit supplies power to the...

Page 14: ...S WKLV RVHG WKH HQJLQH KH UHOD LV RSHQHG WDQGE PRGH XQWLO Stop terminals er installed If your ote Emergency r switch to these without either the stalled er failure relay input troller als These he connection of a mote annunciation on or a control ote annunciation eature meets the uiring NFPA110 DC Interconnections to the Automatic Transfer Switch WARNING H VXUH QJLQH HQHUDWRU LV LQ WKH 2 SRVLWLRQ ...

Page 15: ...ion 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 SELECTING THE CORRECT VOLTAGE if equipped A variety of phase voltages are available from the four position selector switch The three basic connection patterns are Low 120 208 High Wye 277 480 and Single Phase 120 240 W...

Page 16: ...control will display the engine information To get the generator information scroll down on the controller The AC ouptut readings displayed on the DSE 7310 MKII are collected through the AC interface harness wired in the generator control box Any shutdowns related to the AC output are a function of the controller are based on information collected in the DSE 7310 MKII via this AC harness 5 After t...

Page 17: ...nly usable in the 120 240V single phase In the 120 208V position the 240V receptacles have only 208V at them Refer to the voltage output table located previously in this manual 2 Full Power Load Connection Terminal Block For remote connections and connecting load distribution boxes heavy duty terminal blocks have been provided These terminal blocks are located on the rear of the unit The neutral a...

Page 18: ...d L3 has been moved to L2 2 The CAN has been connected to the controller 3 P1 and P2 are used for voltage adjustment Installation 057 295 ISSUE 2 Page 18 of 62 3 2 TYPICAL WIRING DIAGRAMS NOTE The DSEA109 AVR is suitable for alternators with a Permanent Magnet Generator PMG Auxiliary Winding or Shunt connections 3 2 1 PMG WINDING CONNECTION WARNING LIVE PARTS exist within the AVR When powered avoi...

Page 19: ...iller plug dip stick filler pipe CAUTION PERSONAL INJURY Only change oil when the engine is not running and is at a low temperature in order to avoid the risk of burns 6 Insert the dipstick and close the oil filler cap 7 Dispose of oil in accordance to local codes DO NOT dispose or allow oil to seep into the ground or sewer systems doing so will cause environmental damage CHANGING OIL FILTER The f...

Page 20: ... the radiator until it is even with the lip of the filler port 3 Reinstall radiator cap CHANGING COOLANT WINCO pipes the coolant to drain to the outside for convenient maintenance Engine coolant contaminated with rust or water scale reduces the cooling effect Even when extended life engine coolant is properly mixed the engine coolant gets contaminated as its ingredients deteriorate Drain flush and...

Page 21: ...ake care to ensure that no dust gets into the sleeve 3 Check that there is no dirt If there is clean the filter element Blow dry compressed air through the filter element from the inside outward maximum pressure 200 kPa Do not use detergents do not use diesel 4 Replace the filter if any breakages or tears are found 5 Reassemble by repeating the above operations in reverse order 6 Reinstall the ele...

Page 22: ...ter first warming up the engine 2 Fill the engine with protective oil type 30 M or alternatively oil that complies with MIL 2160B type 2 specifications up to the minimum level indicated on the dipstick Start the engine and keep it running for approximately 5 minutes 3 Drain the fuel from the injection circuit from the filter and from the injection pump pipes 4 Connect the fuel circuit to a tank co...

Page 23: ... Check Electrolyte Level in Battery and Clean Terminals 6 Months Drain Water from Fuel Pre Filter 600 Hours Check Belts and Belt Tension 600 Hours Change Oil 600 Hours Every 2 Years Change Oil Filters With every oil change Change Fuel Filters 600 Hours Every 1 Year Change Fuel Pre filter 600 Hours Every 1 Year Check Exhaust System for Damage 6 Months Clean Fuel Tank 6 Months Change Auxiliary Membe...

Page 24: ...to the unit Fuel supply shut off Fuel tank empty Air in the fuel system Engine fuel solenoid has not opened Defective fuel pump Defective fuel solenoid Defective engine harness Improper battery voltage to fuel pump or fuel solenoid Engine starts then stops and alarm light comes on Engine oil pressure is low Engine has high water temperature Engine has overspeed Engine has gone into overcrank No ou...

Page 25: ...THHN THHW THW 2 XHH XHHW XHHW 2 ZW 2 SIZE AWG OR KCMIL Wire Type RHW THHW THW THWN XHHW USE Wire Type TBS SA SIS THHN THW 2 THWN 2 RHH RHW 2 USE 2 XHH XHHW XHHW 2 ZW 2 44 57 75 88 101 114 132 154 176 202 224 251 273 295 334 370 405 418 431 458 480 519 550 572 585 50 68 86 100 118 137 155 177 205 237 264 291 319 346 391 432 473 487 505 532 560 605 642 669 683 8 6 4 3 2 1 1 0 2 0 3 0 4 0 250 300 350...

Page 26: ...26 OPM 148 REV A SEE FOLLOWING PAGE FOR REFERENCES if equipped SELECTOR SWITCH WIRING DIAGRAM ...

Page 27: ... 9 51 6 5 37 21 7 33 3 83 7 225 95 02817 1 95 29 5 72 203 16 7 25 5 5 95 7 6 3 87 6 7 6 0 3 1 335 7 7 6 7 66 0 7 7 7 5 1 02 3 57 00 7 6 5 1 217 16 35235 7 5 1 250 7 21 21 1 72 1 2 81 87 25 86 6 352 7 0 61 216 1 53 5 72 5 1 0 1 8 5 ...

Page 28: ...28 OPM 148 REV A DSE 7310 MKII WIRING DIAGRAM ...

Page 29: ...29 OPM 148 REV A WIRING DIAGRAMS THREE PHASE AC WIRE HIGH WYE THREE PHASE AC WIRE LOW WYE THREE PHASE WIRING DELTA SINGLE PHASE AC WIRING 4 LEAD ...

Page 30: ...30 OPM 148 REV A ENGINE HARNESS ...

Page 31: ... A signal range check is performed on the signal Sensor is inside ECU 6C 3 108 4 Environmental pressure sensor is available and connected via hardware to the ECM Pressure is obtained through Analogic to Digital Converter and transformed to a physical value in EnvP_pSens A signal range check is performed on the signal Sensor is inside ECU 6C 4 110 3 Electrical Signal range check of Coolant temperat...

Page 32: ...op switch input For the idle shut down a state machine is used The state in which the state machine is at the moment is shown in the message CoEng_stIdlShDwnStM_mp Assuming the conditions to enable the engine shut off then the engine will shut down after a countdown timer The status signal indicates when the countdown timer is below a timer calibrated CoEng_stIdlShDwnStM_mp 1 252 1F 623 6 The Powe...

Page 33: ...nd trigger appropriate substitute reaction The behavior pattern describes in a bit mask different detected problem overcurrent command collision RAM error short circuit when the expected combination of errors is detected measured and reference pattern are matching a failure is detected 28E 5 654 6 Hardware errors in the injectors and respective ECM power stages are investigated Diagnostic procedur...

Page 34: ... hardware connected sensor The raw voltage signal is acquired in the message Exh_uRawPTrbnUs This signal is checked for the Signal Range Errors and then transformed into physical value Exh_pSensPTrbnUs 4B9 3 1209 4 The turbine upstream pressure is acquired via hardware connected sensor The raw voltage signal is acquired in the message Exh_uRawPTrbnUs This signal is checked for the Signal Range Err...

Page 35: ... is the LowLevel Chipdriver for the Powerstage Chips R2S25200kfp The R2S25200 is a chip with 18 power stages and an additional module for the monitoring of the ECU internal 5V Supply Voltage It is possible to configure max 4 R2S2 B18 C 2840 14 Calibrated parameters for baud rate cannot be read from EEPROM B18 E 2880 2 A range and plausibility check for the value of PTO switch are performed The sou...

Page 36: ...ircuit is monitored separately A plausibility check is made in case a failure Short circuit to Battery SCB or Short circuit to Ground SCG is detected Therefore the switch Low side in case of SCB High side in case of SCG is closed If the Short Circuit failure disappears it is cleared and the Overload failure activated 152B 6 5419 7 The Throttle Valve actuator gives a feedback with a position sensor...

Page 37: ...s or for your failure to ensure the performance of all scheduled maintenance As the off road engine owner you should however be aware that FPT Industrial S p A may deny your warranty coverage if your off road engine or part has failed due to abuse neglect improper maintenance or unapproved modifications Your engine is designed to operate on diesel only Use of any other fuel may result in your engi...

Page 38: ... all the required maintenance listed in the Owner s Manual FPT Industrial S p A will not deny an emission warranty claim solely because no record of maintenance exists however a claim may be denied if failure to perform maintenance resulted in the failure of the warranty part It is recommended that replacement parts used for maintenance or repairs be FPT Industrial S p A service parts to maintain ...

Page 39: ...oration and or contamination 5 Fill the cooling system with coolant If not installed in an application the cooling system connections at the thermostat housing and the water pump must remain dry and closed to limit environmental exposure and or corrosion 6 The engine must be pre oiled before start up see lubrication section for lubrication specifications This involves cranking the engine for one 1...

Page 40: ...held liable for any special indirect consequential or liquidated damages WINCO Inc shall not be liable for any claim that requires replacement of engine part or component of the product that is no longer manufactured or available Additionally WINCO Inc will not be liable for any engine replacement that may require an emissions tier level change THERE ARE NO EXPRESS WARRANTIES OTHER THAN THOSE DESC...

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