WINPOWER CORPORATION

Generating Quality.
Since 7925
GASOLINE ELECTRIC PLANT
AIR COOLED
-
3600 R.P.M.
I
/
EGSA
WINPOWER CORPORATION
NEWTON, IOWA 50208 U.S.A.
PHONE: (515) 792-1301 /CABLE:
WINPOWER
/ TELEX 11: 910-520-1557
Printed in U.S.A
INTRODUCTION
This manual covers the safety, operating and maintenance instructions for the WINPOWER line of
air-cooled generator sets. Included as a part of the package is a parts l i s t and wiring diagram covering
the particular model you have purchased. The engine manufacturer's manual i s also furnished with
the set, and gives the necessary operating and maintenance information for the engine.
GENERAL
The engine generator sets covered by this manual are of the single bearing type. The rotating member
of the generator i s mounted on a tapered extension of the engine crankshaft.
All sets have'been thoroughly tested a t the factory. The normal carburetor and engine speed adjustments have been made.
The set should be carefully inspected upon delivery for evidence of possible shipping damage. If
damage has occurred, a notation should be made on the freight bill, and you should file a claim,
i f necessary. If the damage appears to be of a major nature, the set should not be operated until
the fault has been corrected.
The model number and serial number of the set must be given when contacting the dealer or the
factqry.
*
ELECTRICAL DESCRIPTION
The generators used in the WI NPOWE R line of air-cooled engine generator sets are revolving
armature type.
The static, or electronic excitation system, uses rectifiers t o change part of the output of the
AC generator l o DC for excitation of the field. On most models using static excitation, this
system i s extended s t i l l further by using current feedback through rectifiers in order t o obtain
increasing field strength with load increase t o give better voltage regulation.
OPERATION
ENGINE STARTING
The engine manual should be followed in regards t o operation. The engine crankcase must be
filled with an oil recommended by the engine manufacturer. The fuel should be regular grade
automotive gasoline. When filling the tank, allow for fuel expansion. Never fill tank when engine
i s running, or while engine is hot.
The carburetor choke should be adjusted as required by temperature conditions. When starting
the generator, the operator should assume a stable stance-to prevent injury in the event of engine
kickback. Pull the start rope with a quick, smooth pull, to crank the engine. Be sure t o pull the
rope completely-through until it clears the starting pulley. After the engine starts, return choke
t o i t s normal position. In cold temperatures, it may be necessary to keep the choke in the choke
position longer.
HIGH MOISTURE CONDITIONS
The use of electrical equipment under extremely wet conditions should be avoided.
EXHAUST
Generator units must be operated in a well ventilated area to provide adequate cooling air for
the engine and proper discharge of exhaust fumes.
STAB1LlTY
.
Generator units should be placed on a solid level surface for proper engine operation. I f there i s
any indication that the unit may shift during operation, the use of t i e downs i s recommended.
EXTENSION CORDS
The proper selection of an extension cord is necessary for optimum tool operation. Consult the
following chart for proper wire size to carry the required load current. Voltage drops due t o the
extension cord should not exceed five volts,
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WIRE SIZE
AWG
MAXIMUM
AMPS
4
6
8
10
12
14
16
70
55
40
30
25
18
13
VOLTAGE DROP 8 M A X I M U M AMPS
FOR GIVEN WIRE LENGTHS
25'
.87
1.08
1.25
1.50
1.98
2.27
2.65
50'
1.74
2.17
2.51
3.00
3.97
4.55
5.22
75'
2.60
3.25
3.87
4.50
5.95
6.82
7.84
100'
3.48
4.35
5.03
6.00
7.95
9.10
10.45
MAINTENANCE
ENGINE
Refer t o engine manual.
GENERATOR
Check brush lengths after 500 hours of running and every 100 hours thereafter. If brush length i s
less than
the brush should be replaced with a new one.
%I1,
..
SANDING BRUSHES
It is important that the brushes make good
contact with the collector rings. When
installing a new set of brushes, they
should be sanded in by using 00 sandpaper.
Grit side of
sandpaper
~ h sandpaper
k
should be pulled in the direction of rotation. When pulled in the opposite direction
t o start a new stroke, the brush should be raised. Continue thesanding until the brushes are fully
seated. Do not use emery cloth.
The collector rings should be cleaned if dirty.
Dirt and the moisture it will hold are detrimental t o generators. If dust and dirt accumulate, the
generator should be cleaned periodically.
THE FOLLOWING SERVICE PROCEDURES SHOULD BE PERFORMED BY AUTHORIZED WINPOWER
SERVICE CENTERS OR OTHER QUALIFIED PERSONNEL.
TESTING
FOR OPEN CIRCUITS
The most likely place for an open circuit t o occur is the shunt field circuit. The shunt f'ield i s
connected t o the rectifier output. One end of the shunt field should be disconnected. An ohmmeter reading should be taken between the disconnected end and the other end to determine
continuity. If no reading is obtained, there i s an open circuit. Its exact location should then be
determined and the open circuit should be repaired. The output leads should be checked for
continuity.
RESTORING RESIDUAL MAGNETISM
PROCEDURE
It can be done by applying DC voltage (6-24 volts) across the terminals of the shunt field.
Care must be taken that the polarity i s correct. Incorrect polarity will destroy the diodes in
the rectifier bridge if a limiting resistor i s not used.
TESTING RECTIFIERS AND DIODES
DEFINITIONS
F.
,-w-,
A diode is a single rectifying element represented graphically as shown:
L
When a diode is used alone such as in half wave rectification, it can also be called a rectifier.
Two diodes are used in full wave rectification as shown:
Four diodes are used in a single phase rectifier bridge as shown:
TESTING
An ohmmeter i s required for testing a diode or
rectifier assembly. It i s necessary to remove the
leads going t o the rectifier for testing it. A single
diode will show a very high resistance in one
direction and low resistance in the other direction.
-m+
@-
.
+
V e r y H i g h Reading
Low Reading
Ac
AC
,Y
!,--.
-
A shorted diode will have a low reading in both
directions. An open diode will have a high
reading in both directions. Each diode in an
assembly can be tested as shown:
Low Reading
V e r y High Reading
This reading has t o be repeated on every diode.
If the rectifier assembly i s a molded assembly, t e s t as follows:
Using a volt-amp-ohm meter (multi meter), check the rectifier assembly in the following sequence:
A,
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For purposes of order in checking,
consider one AC terminal as r 1 ,
the other as r 2 .
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Check Between
meter lead on AC #1
+ Meter lead on + terminal + Meter lead on + terminal + Meter lead on -terminal + Meter lead on -terminal + Meter lead on AC el
+ Meter lead on AC el
+ Meter lead on AC ,-2
+ Meter lead on AC ;2
-
meter lead on AC r 2
meter lead on AC r 1
meter lead on AC r 2
meter lead on
+ terminal
meter lead on -terminal
meter lead on + terminal
meter lead on -terminal
Expected
Resistance
Reading
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High
High
Low
Low
Low
High
Low
Hiqh
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If any readings do not comply with the above chart, the rectifier assembly i s defective and should
be replaced.
ECON-0-MIZER MAGNET ADJUSTMENT
INSTRUCTIONS
1. Place Econ-o-mizer switch in off position, s t a r t engine.
2. Manually push Econ-o-mizerarm oncarburetor up or down to reach an idle speed. Adjust
engine idle set screw clockwise to reach 50-60 volts AC at 120 volt receptacle.
3. Stop engine. Adjust magnet up or down so that it just touches the Econ-o-mizerarm. While
holding the arm in idle position, tighten magnet into this position.
4. Turn idle set screw one-half turn counterclockwise so that screw does not touch stop on
carburetor when arm i s against magnet. Adjustment is complete.
5. I f Econ-o-mizerwill not hold at idle, off load and switch turned on, adjust the magnet
farther from the carburetor arm.
TROUBLE SHOOTING CHART
TROUBLE
REMEDY
CAUSE
No output voltage
Loss of residual magnetism.
residual magnetism.
'
Low output voltage at
no load.
Defective diode in rectifier
bridges (see instructions for
testing rectifier bridges).
Replace diode or rectifier
assembly.
Poor brush contact (brush
can be stuck in holder, worn
or spring can be weak).
Free brush i f stuck. Replace
with new brush i f worn.
Replace brush spring i f weak.
Open circuit (see instructions
for testing of open circuits).
Complete circuit if in external
wiring.
Shorted armature coils i n
revolving armature unit.
Replace armature.
Engine speed too low.
Adjust engine speed to correct
value.
Low engine speed.
Adjust engine speed to correct
value.
Shorted diode (see instructions Replace diode or rectifier
for testing rectifier bridge).
assembly.
-
0.k. at no load,
but drops off rapidly on
load application.
Shorted diode in series field
bridge (see instructions for
testing rectifier bridge).
Replace diode or rectifier
assembly.
Engine speed drops off rapidly.
See engine manual.
High output voltage
Excessive engine speed.
Adjust'engine speed to correct
value.
Excessive.generator
heating.
Overload on generator.
Reduce load.
clogged ventilating inlets
and/or outlets.
Clean inlets and outlets.
Brushes not seated properly.
See instructions for sanding
brushes.
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Arcing a t brushes
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MODEL
TYPE
PAilT . NO.
REF.
DESCRIPTION
N.S.
1
2
3
4
5 .
6
7
8
9
10
Engine-Briggs & S t r a t t o n
~ i b r ai o
tn
C a r r y i n g Frame
Generator Support
panel S u p p rt F i e l d coil
Armature S t u d
Fan
End Hood
Field ~ r ' . a k
Bearing .
~rmature"
D r i v e End B e l l
Stud
N o t Applicable
L i f t Eye
F i e l d Frame . ~ s s & = i .~.
Field Coil
Coil Shield
Field Pole
Brush Gear Assembly
Diode
Heat S i n k
Generator Support
Rectifier
Brush S p r i n g
Brush
Studs
Diode R e v e r s e P o l a r i t y
R e c e p t a c l e L5-20R
C i r c u i t B r e a k e r 20A
Not A p p l i c a b l e
Duplex R e c e p t a c l e 5-20R
P a n e l Box
P a n e l Top
R e c e p t a c l e 6-50R
Brush Ring
C i r c u i t B r e a k e r 30A
C i r c u i t B r e a k e r 40A
Back P l a t e
R e c e p t a c l e L6-30R
Panel Side
Panel Side
Economizer ~ o d u l e
SPST T o g g l e S w i t c h
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
N.S.
N.S.
N.S.
,-N ,S.
.
,
Economizer Electromaanet
Wiring Diaqram
P a r t s Drawlna
IF-5552-1.
IE-11794
8COOBEP/IC
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QTY
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OWNER'S
S E R V I C E
RECORD
CONSULT E N G I N E MANUALFOR SUGGESTED
MAINTENANCE AND S E R V I C E I N T E R V A L S
CONSULT GENERATOR S E T OWNER'S MANUAL
FOR GENERATOR S E R V I C E AND M A I N T E N A N C E
G E N E R A T O R SET:
Model No.
S e r i a l No.
P u r c h a s e d From
Placed i n Service
ENGINE :
Type
Model
S e r i a l No.
I
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