PTO SERIES OWNERS MANUAL - Electric Generators Direct

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MODEL: PTO 15/12MODEL: PTO 30/25MODELS: PTO 40, 50, 55,65, 70, 75, 90, 110 SERIESPTO SERIES OWNERS MANUALPTO 15/12, PTO 30/25PTO 40-1, PTO 50-1, PTO 65-1, PTO 75-1PTO 55-3, PTO 70-3, PTO 90-3, PTO 110-3Form 2593-PTOREV. 7/06

TABLE OF CONTENTSSAFETYTRAILER MOUNTINGTHREE POINT HITCHOPERATINGFULL POWER CONNECTORGROUNDINGSHAFT INSTALLATIONGEAR BOXMAINTENANCEMOUNTINGSafety FirstWhile safety is built into everygenerator, imprudent operation,negligent maintenance or carelessnesscan contribute to present serioushazards to life and injury.Keep a fire extinguisher nearby. Knowits proper use. Consult your local firedepartment for the correctextinguisher type. Extinguishers ratedABC by the NFPA are appropriate formost applications. Annually servicethe extinguishers and perform serviceas required.Be sure the generator is wellventilated. Do not operate thisgenerator in an enclosed compartment.All warranties are voided if operated inan enclosed compartment.Provide adequate ventilation for theprime mover engine on the tractor.The output power voltage presentin this equipment can cause a fatalelectric shock. This equipmentmust only be operated by a responsibleadult.Do not allow anyone to operate thegenerator without proper instructions.Guard against electric shock.Avoid direct contact with liveterminals or receptacles.Do not operate this unit in rainor snow.Use only 120 volt 3-wire groundedplugs and 240 volt 4-wire groundedplugs, connectors and extension cords.This unit must be properly groundedby the operator according to theNational Electric Code and theOccupational Safety and HealthAdministration (OSHA).22&3333&444&9445&6ISOLATION SWITCH6&7WIRING DIAGRAMS8&9PARTS EXPLOSIONS10,11,12,13,14&15ADJUSTING VOLTAGE16OPERATING SHAFT SPEED16GUARDS169CONNECTIONS17ORDERING PARTS18WARRANTY18All pulleys, shafts, belts must beprotected with safety guardsproperly installed before operatingthe equipment.When working on or around thisgenerator, do not wear neckties orloose clothing, jackets or sleeves thatmay become caught in moving parts.Only a qualified technician shouldperform repairs on this equipment.Do not work on this equipment whilefatigued or under the influence ofalcohol or drugs. Use extreme cautionwhen working on electricalcomponents. High output voltagesfrom this equipment can cause injuryor death.When working around engines usenoise suppression equipment andwear protective devices as necessary.Excessive noise is not only tiring, butcontinual exposure can lead to lossof hearing.Installing and wiring a home orbuilding to a PTO generator is not ado-it-yourself project. Consult aqualified licensed electrician orcontractor. This installation mustcomply with all national and localelectrical codes.Do not connect this generator to ahome or building except through anisolation transfer switch (double poledouble throw).When wiring an electrically drivenpump, follow all electrical and safetycodes, as well as the most recentUnited States National Electrical Code(NEC) and the Occupational Safety andHealth Act (OSHA).2Safety SymbolsThese symbols alert you to potentialpersonal injury situations. Follow theInformation to avoid possible injuryor death.This symbolindicates imminenthazardous situations, which, if notavoided, WILL result in death or seriouspersonal injury.This symbolindicates apotentially hazardous situation,which, if not avoided, COULD resultin death or serious personal injury.This symbolindicates apotentially hazardous situation,which, if not avoided, MAY result inpersonal injury.Visual InspectionVisually inspect the unit before theinitial start. Check for loose or missingparts and any damage that may haveoccurred in shipment. You mustremove the generator from thewooden mounting base.Ground MountingSee figures 1 and2 for installationon a concrete slab with mountingdimensions. Failure to mount securelywill result in damage to the generatorand possible personal injury or death.Trailer Mounting(Optional Accessory) 3403See figure 3 for atypical example ofa trailer. Mount the generator on atrailer if you plan to use the generatoras a portable source of power. Thetrailer should first be connected to thetractor. Next the generator should be

placed on the trailer and connectedwith the shaft to the tractor andgenerator. IMPORTANT The generatorMUST be mounted forward of thetrailer axle to prevent the trailer fromtipping backwards which can causepersonal injury or death. Once thepositioning of the generator, shaft andrelationship to the axles has beendetermined, secure the generator using4 hex bolts of at least 3/8 inch diameterwith washers and nuts. Drilling fourholes will be required. It is stronglyrecommended that the axle length beat least 41 inches before the wheelhubs. This width is recommended toprevent the torque required to turn thegenerator from causing the generatorand trailer from tipping over. Thetrailer height should enable aligningthe drive shaft in a straight or nearlystraight line between the tractor PTOand the generator PTO. Misalignmentmust be less than 10 degrees duringoperation even though the mechanicaldesign of the shaft would allow greatermisalignment. This optional trailer canbe ordered from your local dealer.Three Point Hitch(Optional Accessory)3418See figure 4 fora typical exampleof a three point hitch. Mount the threepoint hitch to the tractor. Place thegenerator on the three point hitch.Attach the shaft to the generator andthe tractor PTO’s. Once the positioningof the generator, shaft and relationshipon the three point hitch has beendetermined, secure the generator using4 hex bolts of at least 3/8 inch diameterwith washers and nuts. The height ofthe generator should enable aligningthe drive shaft in a straight or nearlystraight line between the tractor PTOand the generator PTO. Misalignmentmust be less than 10 degrees duringoperation even though the mechanicaldesign of the shaft would allow greatermisalignment.This optional hitch can beordered from your local dealer. Drillingfour holes will be required.Operating The GeneratorKeep the areaaround thegenerator clear of all debris, rags etc.Do not smoke around the generator ortractor. Be certain the generator isproperly grounded. Turn the main 2pole circuit breaker on the generator tothe off position. Be certain all of thesafety guards are in place. Check thegear box inspection plate to verify thatgear oil is up to the level of theinspection point. Do not overfill the oilin the gear box. Remove any weatherprotective covers that may have beenput over the generator beforeoperating the unit. Make certain thatthe generator is properly mounted on asecure location (concrete slab, trailer orthree point hitch), no people orchildren are around the generator andplug in the electrical load into thereceptacle or full power connector.Make certain that the tractor wheelsare blocked to prevent the tractor frommoving and the parking brake isapplied. Start the tractor and at lowidling speed engage the PTO to thegenerator. Slowly bring up the speed inthe generator until the volt meterreads at least 240 volts on the PTO15/12 and PTO 30/25 (which is 60 hertz)or 60 hertz on the other PTOs (which is240 volts) and lock the tractor speed.Lower voltage, below 240 volts orbelow 60 hertz is worse than slightlyhigher voltage or slightly higherfrequency. When the tractor andgenerator are operating properly, turnthe isolation switch from the utilityposition to the off position and then tothe generator position. Next, switchthe main 2 pole circuit breaker on thegeneratorto the on position and you are nowbeing powered by the PTO generator.Do not open any protective covers,control panels, etc. while the generatoris operating.When it is time to stop operating thegenerator, you must first remove eitherthe electrical load from the generator3circuit breaker to the off position.Do not slow the generator speed downwith an electrical load on the generatoror damage to the generator and loadwill occur. Bring the tractor PTO speeddown to idle and shut the tractor PTOoff. You would then switch theisolation switch back to normalutility power.Isolation Switch andIsolation CircuitsSee figure 5 for the proper installationof a customer supplied isolation switch.Installation of anisolation switchmust be done by a licensed electrician.Back feeding of electrical power from agenerator without a proper isolationswitch installed can kill servicepersonnel working on power linesand/or damage equipment when theutility returns normal power. See figure5 for a sample wiring of an isolationswitch. Do not operate this generatorin parallel with another generator. Theisolation switch has three positions,utility position, off and generatorposition. The National Electrical Codeand local codes require an isolationswitch be installed between a standbygenerator (such as a PTO generator)and the utility lines. See figures 6 and 7for Isolation Circuits.Full Power ConnectorInstallationSee figures 15 and17 . The connectorhas been assembled at the factory. Onlya licensed electrician should install thewire cables to the connector. Failure toproperly connect the wires will result indamage to the equipment and/orpersonal injury. Consult a wireampacity chart for the proper wiregauge size for a given generator. Youmust use stranded copper weldingcable with a 600 volt rating and aminimum of 3AWG hypalon insulation.The wires must be stripped about 0.75inch from the end of the cable. Insertthe end of the wire into the open

or turn the generator main 2 polecontact. Use a heavy crimping tool tosecure the wire into the contact. Insertthe four contacts into the full powerconnector making certain that they aresecurely in place.GroundingProper groundingwill prevent anelectric shock in the event loss ofinternal ground or loss of a ground inthe load. The National Electric Coderequires at least a number 12AWGstranded copper wire to the groundinglug on the generator. Connect the lugto a copper or brass grounding roddriven into the earth. DO NOT attachground connections to gas or waterpipes.Wiring DiagramsSee figure 8 for PTO 15/12See figure 9 for PTO 30/25See figures 10 and 10A for all otherPTOsTypical InstallationSee figures 5, 6 and 7 for all models.Shaft InstallationSee figure 11 forall models. It isstrongly recommended to keep theangle of the shaft within 10 degreesfrom the tractor PTO and generatorgear box. Do not operate over 540 RPM.A three point hitch requires a shortshaft and a two-wheel trailer andground mounting requires a long shaft.These optional shafts can be orderedfrom your local dealer. Keep guards inplace at all times.Gear BoxThe gear box isa self containedhelical gear unit. It has a glassinspection plate. Be sure to checkbefore using the generator that thegear oil is at the fill line. Use SAE 90gear oil. DO NOT overfill the oil orleaks may occur. The fill location is atthe top of the gear box, inspectionplate is on the side of the gear boxand the drain plug is located on thebottom of the gear box. This gear boxis not to be serviced in the field. Allgear boxes have been filled with gearoil at the factory. The cone guards mustbe in place at all times.Parts ExplosionsSee figure 12 and13 for PTO 15/12See figure 14 and 15 for PTO 30/25See figure 16 and 17 for PTO 40-1,PTO 50-1, PTO 65-1, PTO 75-1,PTO 55-3, PTO 70-3, PTO 90-3MaintenanceIt is recommended to lubricate theshaft with a lithium base grease. In thewinter with freezing conditions, thePTO shaft should be greased with abrush to avoid sticking and freezing.Before using the generator, be sure toclean the generator and remove dirtetc. Barns may contain a lot ofmoisture, dirt and ammonia-type gasesthat can lead to corrosion of copperwire. Store this unit in a clean area. Letthe generator cool down completelybefore placing any protective coverover the generator.To maintainyour generatorunder warranty, you must use originalfactory parts. Use of non factoryoriginal parts will void the warrantyand the manufacturer does not acceptany claims for property damage, injury,death or any other damages caused bythe non factory authorized parts.The gear box oil should be changedevery 250 hours of operation, the shaftshould be lubricated with each use, andthe generator should be tested at leastevery 3 months.4

Figure 1 – Concrete MountingRTOCATR EREHFigure 2 – Concrete Mounting DimensionsMODELABCDEPTO 15/1218.0 (457)9.92 (252)13.625 (346)---21.0 (533)PTO 30/2522.0 (559)13.8125 (351)19.0 (483)---27.0 (686)PTO 40-122.0 (559)13.38 (340)12.2 (310)16.9 (429)27.0 (686)PTO 50-122.0 (559)13.38 (340)12.2 (310)16.9 (429)27.0 (686)PTO 65-122.0 (559)13.38 (340)12.2 (310)16.9 (429)27.0 (686)PTO 55-322.0 (559)13.38 (340)12.2 (310)16.9 (429)27.0 (686)PTO 70-322.0 (559)13.38 (340)12.2 (310)16.9 (429)27.0 (686)PTO 75-126.0 (660)15.9 (406)---13.7 (347)24.0 (610)PTO 90-326.0 (660)15.9 (406)---13.7 (347)24.0 (610)PTO 100-326.0 (660)15.9 (406)---13.7 (347)24.0 (610)544928Figure 3 – Two Wheel Trailer 3403 (Optional), Weight 175lbs., Tires P175/80R13 M S(14” Hub)579.5

33.5538.24.5Figure 4 – Three Point Hitch 3418 (Optional), Weights 92lbs.Figure 5 – Isolation Switch6

UTILITY LINESL N LELECTRIC METERMAIN CIRCUIT BREAKER PANELVARIOUS LOADSON GENERATORVARIOUS LOADS(NOT ON EMERGENCY GENERATOR)POWER RETURN LIGHTGENERATORLISOLATION SWITCHN(SHOWN IN NORMAL POWER FEED)LVARIOUS LOADS(NOT ON EMERGENCY GENERATOR)Figure 6 – Selected IsolationUTILITY LINESL N LELECTRIC METERPOWER RETURN LIGHTGENERATORLISOLATION SWITCHN(SHOWN IN NORMAL POWER FEED)LCIRCUIT BREAKER PANELVARIOUS LOADSVARIOUS LOADSFigure 7 – Total Isolation7

Figure 8 – Wiring Diagram for Model PTO 15/12Figure 9 – Wiring Diagram for Model PTO 30/258

Figure 10 – Wiring Diagram for Single Phase Models PTO 40-1, PTO 50-1, PTO 65-1(PTO 75-1 not shown and does not have a circuit breaker)Figure 10A – Wiring Diagram for Three Phase 240V, Delta Models PTO 55-3, PTO 70-3,(PTO 90-3 and PTO 110-3 not shown do not have a circuit breaker)Figure 11 – Shafts 3397 (long) 57”-67” and 3421 (short) 37”-50”(Length Dimensions are end of hub to end of hub. 1 3/8” 6 spline both hubs)9

Figure 12 – Parts Explosion for PTO 15/12Repair Parts List for Model PTO 15/12ItemPart 328333233493336Rotor Screw CoverEnd CoverGrommetStatorBall Bearing 52 mmFan GuardFan BracketFanFixing RingRotorQuantity112112111110ItemPart 367032813184338233833168-BDiodeVaristerRotor ScrewCapacitor 35 mfBushingTop CoverTerminal StripGear Box Transmission Car 3PSafety ConeBase PlateQuantity2211111111

23242025212622272928Figure 13 – Parts Explosion for PTO 15/12ItemPart 301533771069101110242024Receptacle 50 A, 240 VCircuit Breaker 30 AReceptacle T/L 30 A,240 VControl Box BackCircuit Breaker 50 A, 2 PoleFront PanelCircuit Breaker 20 AReceptacle Duplex 20 A, 120 VGround LugVolt MeterQuantity121111111111

Figure 14 – Parts Explosion for PTO 30/25ItemPart 365336833553184Bracket PTO SideBall Bearing 90 mmFanDiodeStatorBall Bearing 80 mmSpring WasherBracket (Control Box Side)CoverTerminal StripQuantity111111111112ItemPart -LH33573358338333813360Capacitor 30 mfCapacitor 40 mfTop CoverLifting HookRotorFan GuardSafety ConeGear Box M5ChannelQuantity211112112

2122202319242528182626Figure 15 – Parts Explosion for PTO 30/25ItemPart 121069101110243375-F337933793380Volt MeterCircuit Breaker 100 A, 2 PoleReceptacle T/L 30 A, 240 VCircuit Breaker 30 ACircuit Breaker 20 AReceptacle Duplex 20 A, 120 VGround LugFront PanelConnector (Assembly of 2)Connector Male loose (2)Connector HandleQuantity111211111111327

Figure 16 – Parts Explosion for PTO 40-1, PTO 50-1, PTO 65-1, PTO 75-1, PTO 55-3, PTO 70-3, PTO 90-3, PTO 110-3Item123455A6789Part 3673FanRotorExciter ArmatureDiode Bridge with DiodesBall Bearing 6312.2RSBall Bearing 6309.2RSStatorExciter StatorBracket (Non PTO Side)End CoverQuantity111111111114ItemPart 364636573650365836623383Automatic Voltage RegulatorMounting Plate Control BoxTerminal StripSide PanelsTop CoverStator Thru BoltsFan BracketFan GuardGear Box transmission M7, M9Safety ConeQuantity1112141111

20292122231924SINGLE PHASE25NEUTRALLINEGROUNDLINETHREE PHASE282627LINELINELINENEUTRALFigure 17 – Parts Explosion for PTO 40-1, PTO 50-1, PTO 65-1, PTO 75-1, PTO 55-3, PTO 70-3, PTO 90-3, PTO 110-3ItemPart 88310693673101110243512347933793380Connector CoverReceptacle 50 A, 240 VCircuit Breaker 50 A, 1 poleCircuit Breaker 20 AFront CoverReceptacle Duplex 20 A, 120 VGround LugCircuit Breaker 175 A, 2 PoleFrequency (Hertz) MeterConnector Male Loose (2)Connector HandleQuantity11211111111ItemPart No.*3569PTO 40-1 125A, 2 Pole3570PTO 50-1 175A, 2 Pole3571PTO 65-1 225A, 2 Pole3572PTO 55-3 150A, 3 Pole3379 and 3380 Used on PTO 40-1,PTO 50-1 and PTO 55-3350AUsed on PTO 65-1,PTO 75-1,PTO 70-3, PTO 90-3 and PTO 110-3****Description* Model PTO 50-1 shown(Models PTO 75-1, PTO 90-3 and PTO 110-3, do not come with a main line circuit breaker. customer supplied)15Quantity111111

Adjusting Voltage for PTO’sAll PTO’s with 12 wireunits feature anautomatic voltage regulator that willmaintain /- 1 ½% voltage regulation.The voltage regulator is preset at thefactory for the required voltage. If achange in voltage is required, thefrequency meter MUST be connected toone line (hot) wire and to the neutralconnection for the meter to function.On a three phase 240 volt series deltaconnection, there is no neutral. Forneutral conncection you must use thecenter tap(CT) adjacent to the lineconnection you choose. With thefrequency meter operating at 60 hertz(50 hertz for 50 hertz operation and thejumper installed) you can increase ordecrease the voltage by simply adjustingthe Phillips screw marked VOLTS on theautomatic voltage regulator.See connections/reconnections pageThe generator mustbe operating at theproper speed (RPM) before and whileadjusting the voltage regulator. Turn theVOLTS adjusting screw very slowly stopand wait 2 or 3 seconds and read thevoltage from one of the lines andneutral connection (note that on thethree phase 240 volt series deltaconnection there is no neutral so youmust go to the center tap as a neutral.Adjust the voltage up or down byturning the VOLTS clock wise or counterclock wise. Once the voltage is adjusted,do not adjust any of the other Phillipsscrews on the automatic voltageregulator. Refer to the re connectionchart if you are changing voltages. Nearthe automatic voltage regulator are themain power terminals of the generator.If you make contact with the mainterminals, serious injury and death willoccur. These adjustments MUST be doneby a licensed electrician or technicianfamiliar with high voltage equipment.This is NOT a do it yourself activity.From the automatic voltage regulatorterminal 4 a green wire always goes tostator lead wire 3. From the automaticvoltage regulator terminal 5 a blackwire always goes to stator lead wire 4.This applies to single and three phaseunits both 50 and 60 hertz and anyvoltage combination. On 60 hertzversions, single and three phase and anyvoltage combination,there is a small brass jumper connectedon the automatic voltage regulatorbetween terminal 5 and terminal 6. For50 hertz operation, this jumper isremoved.Adjacent to the automatic voltageregulator is the radio suppressor onsome models. The lead wires from theradio suppressor are always red andmust go to the stator leads wires 5, 7, 9and 12 on any version in single or threephase., 50 or 60 hertz and any voltagecombination. Some leads may be onthe same terminals as other dependingon the various phase and voltagecombinations.Changing voltage will change theamperage output of the generator. Thecircuit breaker should be changedaccordingly.OPERATING GENERATORSHAFT SPEEDFor 60 hertzoperation thegenerator shaft speed of 1800 RPMmust be continuously maintained. Theoperating speed range is 1700 RPM to1900 RPM for 60 hertz. Shaft speed ofthe gear box connected to thegenerator is either 540 RPM or 1000RPM depending on the model. Slightlylower gear box speed(about 520 RPMfor the 540 RPM on/or 970 RPM for the1000 RPM unit is acceptable, thefrequency meter at 60 hertz is how todetermine proper speed. These are NOTvariable speed generators.GUARD FOR PULLEYS, BELTSAND COUPLINGSAll rotatingequipment MUSTbe equipped with guards to preventcontact with rotating shafts, pulleys,belts and couplings. The customer isresponsibleforinstallingtheappropriate guards. Serious personalinjury or death could result withoutproper guards in place while thegenerator is in operation.16

PTO Series Connections/RE Connections 60 Hertz 12 Wire GeneratorsSINGLE PHASE 120/240 VOLTSPARALLEL ZIG ZAGSINGLE PHASE 120/240 VOLTSDOUBLE DELTAL1 LINEL2 LINEL3 LINEN NEUTRALCT CENTER TAPTHREE PHASE 120/208 VOLTSPARALLEL STARTHREE PHASE 240 VOLTSSERIES DELTA (NO NEUTRAL)CT CENTER TAPDO NOT USEOTHERCONNECTIONTERMINALSVOLTAGEREGULATORSTHREE PHASE 277/460/480 VOLTSSERIES STARFOR 50 HERTZ CONNECTIONS,CONSULT THE FACTORY.17

ORDERING PARTSInstructions For Ordering Repair PartsFor parts or service, contact either the factory or the dealer or distributor from whom you purchased thisequipment for the name of the nearest authorized service station.1. To avoid errors or delay in filling your parts order, please furnish all information requested and alwaysrefer to the nameplate on your unit by giving the model and serial number.2. Do not order by reference number or group number. Always use part number and description.3. Give the part number, description and quantity needed for each item.4. State definite shipping instructions. Any claim for loss or damage to your unit in transit should be filedpromptly against the transportation company making the delivery. Shipments are complete unless thepacking list indicated items are back ordered.5. FOR SERVICE OR PARTS CONTACT THE FACTORY AT:Wanco/Voltmaster 5870 Tennyson Street, Arvada, Colorado 80003.Phone 800-730-3927 Fax 303-427-5725FIVE/ONE YEAR LIMITED WARRANTY- PTO SERIESFive year limited warranty on parts and a 1year limited warranty on labor.This warranty extends to the original purchaser only. The generator sold is warranted to the originalpurchaser for a period of five (5) years for parts only and one (1) year for labor only from the originalpurchase date. The manufacturer warrants the generator sold to be free from defects in material andworkmanship if properly installed, serviced and operated within nameplate rating under normalconditions according to the manufacturer's instructions.DisclaimersThis warranty does not apply to any items which must be repaired or replaced due to normal wear, whichhave been subject to misuse, negligence, accident or which have been repaired, altered by othersoutside of the manufacturer's factory unless authorized in writing by the manufacturer. Under nocircumstances will the manufacturer be liable for any or consequential damage or expense of any kind,including loss of profits nor the fitness of the product for any specific application or particular purpose.Any implied warranties are limited in duration to the above one (1) year period. Some states do not allowlimitations on how long an implied warranty lasts, so the above limitation or exclusion may not apply toyou. This warranty gives you specific legal rights, and you may also have other rights, which vary fromstate to state.PerformanceThe manufacturer's obligation under this warranty is limited to correcting without further charge at itsfactory or authorized service station any part or parts which shall be returned transportation chargesprepaid, and which upon examination shall disclose to the manufacturer's satisfaction to have beenoriginally defective. Other than transportation charges, no charge will be made for such repairadjustment and /or replacement. This remedy is expressly in lieu of all other remedies, and is thepurchaser's sole and exclusive remedy hereunder.18

Operating The Generator Keep the area around the generator clear of all debris, rags etc. Do not smoke around the generator or tractor. Be certain the generator is properly grounded. Turn the main 2 pole circuit breaker on the generator to the off position. Be certain all of the safety guards

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