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Summary of Contents for Winpower DR20
- Page 1 DIESEL GENERATOR SYSTEMS DR20 - DR600 With DGC-2020 Engine Control INSTALLATION AND OPERATIONS MANUAL DR45I4 Shown for Comparison...
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Page 2: Table Of Contents
RECEIVING THE GENERATOR USING THIS MANUAL Unpacking the unit Lifting the unit Congratulations on your choice of a Winpower genera- ENGINE GENERATOR INSTALLATION tor set. You have selected a high-quality, precision-engi- Installation neered generator set designed and tested to give you years Engine Generator Set Mounting of satisfactory standby service. -
Page 3: Guide To Product Safety
FIRE HAZARD - Deisel fuel presents a hazard of possible IMPORTANT SAFETY explosion and/or fire. INSTRUCTIONS Do not smoke or use open flame near the generator set. Keep a fire extinguisher nearby and know its proper use. SAVE THESE INSTRUCTION Fire extinguishers rated ABC by NFPA are appropriate. -
Page 4: Basic Information
Engine Control Module (ECM) with an LCD digital display. The GENERATOR OUTPUT IN KILOWATTS WITH STANDBY Generator Set ECM control is mounted on a vertical pedestal on the right side of the generator. (Except for the DR10 & DR20 which are GASEOUS FUEL TYPE N = NATURAL GAS... -
Page 5: Dgc-2020 Engine Control Layout
Typical Winpower Nameplate Be sure to have the main WINPOWER unit data plate information recorded inside the front cover of this manual for future reference and for identification whenever requesting field or factory technical assistance. - Page 6 quick and simple DGC-2020 operation. Basler Electric communica- A - DGC-2020 Digital Gen-Set Control. See Explanation tion software (BESTCOMSPlus) allows units to be easily custom- below. ized for each application. A wide temperature-range liquid crystal display (LCD) with backlighting can be viewed under a variety of B - DC Control Circuit Fuse.
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Page 7: Dgc-2020 Display Operations
Metered engine parameters include oil pressure, coolant move downward through the menu levels and the left-arrow temperature, battery voltage, speed, engine load, coolant level button is pressed to move upward. Within a level, the up-arrow (from ECU), ECU specific parameters, and run-time statistics. and down-arrow buttons are used to move among items within the menu level. -
Page 8: Receiving The Generator
Optional accessories (i.e. remote annunciator) by the bulk, size, and a means available to unload the generator at the receiving end. WINPOWER recommends units that are shipped 3. Remove main frame hold down bolts. by common carrier be delivered to a commercial dock to allow the Generator Set to be unloaded in a safe, efficient manner and to 4. -
Page 9: Lifting The Unit
Depending on generator set size and configuration, the exhaust WINPOWER has designed all of its Generators Sets to be lifted at system may ‘ship loose’ with the generator set for installation on the corners with an appropriate lifting rig. The lifting points are site. -
Page 10: Engine Generator Set Mounting
FUEL INSTALLATION *************** ***** WARNING **** The fuel supply should be as close to the engine as possible. This *************** will reduce the installation cost of fuel runs and minimize line losses. PERSONAL INJURY - Before proceeding with the installation, The diesel fuel supply should be no more than 3 feet below the fuel be sure the DGC-2020 is in the "stop"... -
Page 11: Battery Installation
Always wear full eye protection and protective clothing INSTALLING THE BATTERY Where electrolyte contacts the skin, wash off immediately **** CAUTION **** with water If electrolyte contacts the eyes, flush thoroughly and immedi- In the following battery installation procedure, check to be ately with water and seek immediate medical attention sure the DGC-2020 is in the “stop”... -
Page 12: Mounting The Transfer Switch
** NOTICE ** A.C. ELECTRICAL The trickle charger is not intended to recharge a battery CONNECTIONS which has become completely discharged. It is designed to produce just enough current to maintain a fully charged NOTICE - CLASS 1 WIRING METHODS ARE TO BE USED FOR battery. - Page 13 CUSTOMER CONNECTION BOX FOR Please refer to the circuit breaker installed on your unit for BOTH AC & DC CONNECTION breaker lug capacities and proper torque specifications. 150 kW THROUGH 400 kW To select the proper conductor size between the Generator and the ATS, first look your model up in Table 1 of Appendix "A"...
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Page 14: Dc Electrical Connections
All wires should be installed in rigid or flexible conduit. (Knock- ESTOP- & ESTOP+ - Remote Emergency Stop terminals. These outs are provided in the control box). two terminals are shipped with a jumper installed. If your applica- tion requires the installation of a Remote Emergency Stop switch, See the manual shipped with the Automatic Transfer Switch for remove the jumper and wire your switch to these terminals. -
Page 15: Initial Start-Up
************* ASCO 165 UL SWITCH ***** WARNING ***** Your DC connection points in the ASCO 165 ATS are ************* terminals “4” and “5 on the interface terminal block. 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. -
Page 16: Exerciser Clock
To test the Automatic Transfer Switch follow the instruction in the ENGINE CRANKS BUT WILL NOT START operators manual you received with your transfer switch. If you get a fault light during the initial start up or prior to start up it is Improper fuel delivery to the unit. -
Page 17: Appendix Directory
120/208 VOLT THREE PHASE PAGE 20 277/480 VOLT THREE PHASE PAGE 20 VOLTAGE REGULATOR CONNECTION PAGE 15 GENERATOR CONTROL PANEL WIRING DR20 PAGE 21 DR45, DR65, DR90, DR130, DR200 PAGE 22 DR175, DR250, DR300, DR350 PAGE 23 DR400, DR500, DR600... - Page 18 APPENDIX 1 SPECIFICATIONS TABLES MODEL WATTS VOLTS AMP HZ PH ENGINE ENGINE BATTERY FULL LOAD MODEL VOLTAGE BCI/CCA FUEL REQ. DR20I4-A 20,000 120/240 ISUZU 4LE2 12 VOLTS 24/650 1.8 GAL DR20I4-D 20,000 120/208 ISUZU 4LE2 12 VOLTS 24/650 1.8 GAL DR20I4-J 20,000 120/240...
- Page 19 APPENDIX 2 The table below is based on Table 310.16 in the National Electric Code 2008 Edition Allowable ampacitier of insulated condutors rated 0 through 2000 volts, 75 C through 90 C. Not more than three current-carrying conductors in Raceway, Cable or Earth (Direct Buried). Adjusted for 40 C (104 ambient temperature.
- Page 20 APPENDIX 3 WIRING DIAGRAMS CROSS REFERENCE MODEL WATTS VOLTS PHASE AC CONNECTION DC ENGINE ENGINE WIRING DIAGRAM CONTROL HARNESS DR20I4-A 20,000 120/240 SINGLE PAGE 19 PAGE 22 PAGE 25 DR20I4-D 20,000 120/208 THREE PAGE 20 PAGE 22 PAGE 25 DR20I4-J 20,000 120/240 THREE...
- Page 21 8122-00 60708-142 Page 19...
- Page 22 8122-00 Page 20 60708-142...
- Page 23 ENGINE CONTROL DR20 8122-00 60708-142 Page 21...
- Page 24 ENGINE CONTROL DR45, DR65, DR90, DR130, DR200 Page 22 8122-00 60708-142...
- Page 25 ENGINE CONTROL DR175, DR250, DR300, DR350 60708-142 Page 23 8122-00...
- Page 26 ENGINE CONTROL DR400, DR500, DR600, Page 24 8122-00 60708-142...
- Page 27 60708-142 Page 25 8122-00...
- Page 28 Page 26 8122-00 60708-142...
- Page 29 60708-142 Page 27 8122-00...
- Page 30 Page 28 8122-00 60708-142...
- Page 31 APPENDIX 4 GENERATOR CROSS REFERENCE MODEL BASE VOLTS PHASE WINCO P/N NEWAGE WINDING GENERATOR MODEL # GROUP LEADS DR20I4-A 300545-1 120/240 SINGLE 350097-91 BCI184E DR20I4-D 300545-2 120/208 THREE 350097-9 BCI184E DR20I4-J 300545-2 120/240 THREE 350097-9 BCI184E DR20I4-L 300545-2 277/480 THREE 350097-9 BCI184E DR45I4-A...
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Page 32: Month Warranty
WINPOWER’s sole liability, and Purchaser’s sole remedy for a failure under this warranty, shall be limited to the repair of the product. At WINPOWER’s option, material found to be defective in material or workmanship under normal use and service will be repaired or replaced. For warranty...
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