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Installation Guidelines For 60 Hz EcoGen™ Generators

iii

Section 1: Safety Rules & General 

Information

Introduction ..................................................................1

Read This Manual Thoroughly ....................................1

Safety Rules  .................................................................1

How to Obtain Service .................................................2

General Hazards ...........................................................2

Exhaust Hazards  ..........................................................3

Electrical Hazards  ........................................................3

Fire Hazards  .................................................................3

Explosion Hazards .......................................................4

Battery Hazards ............................................................4

General Rules ...............................................................5

Before You Begin  ........................................................5
NEC Requirements  .....................................................5
Standards Index  ..........................................................6

Section 2: Unpacking and Inspection

General ..........................................................................7

Required Tools .............................................................7

Unpacking .....................................................................7

Opening the Lid  ...........................................................8

Enclosure Panel Removal  ...........................................8

Remove Front Access Panel .......................................8
Intake Side Panel Removal  .........................................9

Customer Connections and Loose Parts ...................9

Rear Connections  ........................................................9

Generator Main Line Circuit Breaker  .......................10

Parts Shipped Loose  .................................................10

Auxiliary Shutdown Switch .......................................11

Section 3: Site Selection and Preparation

Site Selection  .............................................................13

Carbon Monoxide .......................................................13

Carbon Monoxide Detectors ......................................13
Potential CO Entry Points ..........................................14
Protect the Structure  .................................................14
Distance Requirements  .............................................15
Fire Codes, Standards, and Guidelines  ....................16
Generator Maintenance .............................................16

Fresh Air for Ventilation and Cooling  ......................16

Water Ingress Avoidance  ..........................................16

Proximity to Utilities  ..................................................16

Verify Wi-Fi Range  ....................................................16

Transportation Recommendations ..........................17

Suitable Mounting Surface ........................................17

Placement on Roofs, Platforms, and Other 
Supporting Structures ...............................................17

Section 4: Generator Placement

Generator Placement .................................................19

Fascia Installation (If Applicable)  .............................19

Base Plug Installation (If Applicable) .......................20

Section 5: Fuel Conversion / Gas 

Connections

Fuel Requirements and Recommendations  ............21

BTU Content ..............................................................21
Fuel Pressure  ............................................................21

Fuel Conversion .........................................................21

Fuel Consumption  .....................................................22

Fuel Line Sizing ..........................................................22

Natural Gas Pipe Sizing  ............................................23
LP Gas Pipe Sizing  ...................................................23

Installing and Connecting Fuel Lines  ......................24

Fuel Shutoff Valve  .....................................................24
Flexible Fuel Line  ......................................................24
Sediment Trap ...........................................................24

Checking Fuel Line Connections  .............................25

Checking Fuel Pressure  ............................................25
Performing Fuel System Leak Test  ...........................25

Section 6: Electrical Connections

Generator Connections  .............................................29

Control Wiring  ............................................................30

Main AC Wiring  ..........................................................31

Service Entrance Decals  ...........................................31

Common Alarm Relay (Option) .................................31

Battery Requirements ................................................32

Battery Installation .....................................................32

Connecting Battery ....................................................32

Battery Disposal .........................................................33

Table of Contents

Summary of Contents for 15 kW EcoGen

Page 1: ...duct support lookup Pour le fran ais visiter http www generac com service support product support lookup Register your Generac product at WWW GENERAC COM 1 888 GENERAC 888 436 3722 000209b WARNING Los...

Page 2: ...safety inspections to verify all maintenance for safe operation is performed promptly and to have the equipment inspected periodically by an IASD Normal maintenance service and replacement of parts a...

Page 3: ...and Guidelines 16 Generator Maintenance 16 Fresh Air for Ventilation and Cooling 16 Water Ingress Avoidance 16 Proximity to Utilities 16 Verify Wi Fi Range 16 Transportation Recommendations 17 Suitab...

Page 4: ...l Checks 41 Off Grid Mode DISABLED 41 Off Grid Mode ENABLED 41 Generator Tests Under Load 42 Off Grid Mode DISABLED 42 Off Grid Mode ENABLED 42 Checking Automatic Operation 43 Off Grid Mode DISABLED 4...

Page 5: ...responsible for correct maintenance and safe use of the unit This manual must be used in conjunction with all other supporting product documentation supplied with the product SAVE THESE INSTRUCTIONS...

Page 6: ...aintain this equipment Failure to follow proper installation requirements could result in death serious injury and equipment or property damage 000247a Equipment damage This unit is not intended for u...

Page 7: ...150 Electrocution Never connect this unit to the electrical system of any building unless a licensed electrician has installed an approved transfer switch Failure to do so will result in death or seri...

Page 8: ...e extremely flammable and explosive No leakage of fuel is permitted Keep fire and spark away Failure to do so will result in death or serious injury 000151a DANGER Explosion and fire Connection of fue...

Page 9: ...porated into the transfer switch distribution panel The transfer switch provided with this generator has a distribution panel which will accept AFCIs pre wired transfer switches only Siemens Part No Q...

Page 10: ...ases 7 NFPA 68 Standard On Explosion Protection By Deflagration Venting 8 NFPA 70E Standard For Electrical Safety In The Workplace 9 NFPA 110 Standard for Emergency and Standby Power Systems 10 NFPA 2...

Page 11: ...fter delivery separate damaged materials and contact carrier for claim procedures Concealed damage is understood to mean dam age to contents of a package not evident at time of delivery but discovered...

Page 12: ...one on each side Press down on lid above side lock and unlock latch to correctly open lid Figure 2 4 Opening the Lid 3 Repeat for other side Lid may appear stuck if pres sure is not applied from the t...

Page 13: ...Intake Side Panel Removal Customer Connections and Loose Parts See Figure 2 7 and Figure 2 8 for customer connections and loose parts location Figure 2 10 illustrates parts shipped loose Figure 2 7 Cu...

Page 14: ...OTE DO NOT leave generator MLCB generator dis connect locked in the OFF OPEN position during nor mal generator operation Leaving generator MLCB generator disconnect in the OFF OPEN position will preve...

Page 15: ...r possible perform primary shutdown procedure before disabling generator with auxiliary shut down switch See Figure 2 12 There is also an auxiliary shutdown switch located inside the generator Figure...

Page 16: ...Unpacking and Inspection 12 Installation Guidelines For 60 Hz EcoGen Generators This page intentionally left blank...

Page 17: ...exhaust contains carbon monoxide CO a poisonous potentially lethal gas that cannot be seen or smelled The generator must be installed in a well venti lated area away from windows doors and openings Th...

Page 18: ...l correctly when closed C Attic vent Attic vents ridge vents crawl space vents and soffit vents can all admit generator exhaust D Basement windows Windows or hatches allowing ventilation to or from lo...

Page 19: ...front and ends of generator must be 3 ft 0 91 m This includes shrubs bushes and trees B Rear clearance Fuel and electrical connections are made here 18 in 457 mm minimum clearance per SwRI testing lab...

Page 20: ...the front and ends of the enclosure This includes trees shrubs and bushes Vegetation not in compliance with these clearance parameters could obstruct air flow In addition exhaust fumes from the gener...

Page 21: ...tor on all sides when using pea gravel or crushed stone Figure 3 4 Pea Gravel or Crushed Stone Concrete pads must be appropriately sized in accor dance with national state or local building codes Veri...

Page 22: ...18 Installation Guidelines For 60 Hz EcoGen Generators This page intentionally left blank...

Page 23: ...le Locations Three mounting holes are available if codes require securing generator to concrete Mounting holes are located inside the generator compartment two in front and one in back Three 3 8 in or...

Page 24: ...n If Applicable Proceed as follows to install base plugs 1 Locate the four base plugs supplied with the loose parts See Parts Shipped Loose 2 Locate the four holes in the corners of the generator base...

Page 25: ...uired specification once genera tor is installed See the NFPA website at www nfpa org for further information regarding NFPA requirements Always contact local fuel suppliers or fire marshal to ver ify...

Page 26: ...end of an existing low pressure system Generator Natural Gas Propane 1 2 Load Full Load 1 2 Load Full Load 15 kW 5 52 195 7 87 278 1 84 6 95 66 8 2 76 10 45 100 Natural gas is in m3 h ft3 h Propane i...

Page 27: ...size diameter to include any fittings valves must be full flow elbows tees or angles See Table B 3 2 in NFPA 54 or Table A 2 2 in the ICC IFGC Equivalent Lengths of Pipe Fittings and Valves for the c...

Page 28: ...K8752 3 4 in ball valve part number 0K8754 1 in ball valve part number 0K8184 1 1 4 in ball valve part number 0L2844 1 1 2 in ball valve part number 0L2845 Flexible Fuel Line See Figure 5 2 When conne...

Page 29: ...for future tests of the gener ator while starting running and under loads Performing Fuel System Leak Test All products are factory tested before shipping to verify the performance and integrity of th...

Page 30: ...al fuel shutoff valve pressure port optional Must be located no more than 6 ft 1 83 m away from fuel inlet D Pipe fittings field supplied E Flexible fuel line F Verify clearance with gas provider Regu...

Page 31: ...o more than 6 ft 1 83 m away from fuel inlet D Pipe fittings field supplied E Flexible fuel line F Verify minimum distance requirements for regulator vent according to local gas codes Regu lator shoul...

Page 32: ...Fuel Conversion Gas Connections 28 Installation Guidelines For 60 Hz EcoGen Generators This page intentionally left blank...

Page 33: ...the generator control circuit wiring is prohibited See instruction manual of the specific engine generator for wiring connection details Recom mended wire gauge sizes for this wiring depends on wire...

Page 34: ...cription ID Description A Control wire terminal block C2 Wire tie for control wires E2 Power lug E2 H Neutral stud B Sense wire terminal block D Neutral lug F Ground stud J Neutral bar C1 Wire tie for...

Page 35: ...oss either connection to 50 of rated load to prevent damage to wires or main line circuit breaker NOTE Tighten all wiring lugs bus bars and connection points to required torque specifications Conducto...

Page 36: ...in lb 8 Nm 2 Connect black negative battery cable B from frame ground to negative battery post Tighten to 70 in lb 8 Nm 3 Install red battery post cover shipped with loose parts NOTE Apply dielectric...

Page 37: ...ies in accordance with local laws and regulations Contact your local solid waste collection site or recycling facility to obtain information on local recycling processes For more information on batter...

Page 38: ...Electrical Connections 34 Installation Guidelines For 60 Hz EcoGen Generators This page intentionally left blank...

Page 39: ...to be com pleted successfully See Wi Fi manual for more informa tion NOTE If home Wi Fi network is not available follow instructions on www activategen com Proceed as follows after activating generato...

Page 40: ...Fi man ual If NO continue Press ENTER to begin activation process If ESCAPE is pressed instead of ENTER generator will only run in manual mode for test purposes and NOT ACTIVATED will be displayed Pre...

Page 41: ...to being shipped and does not require any type of break in NOTE The unit comes filled with 5W 30 weight organic oil from the factory Check oil level and add appropriate viscosity and amount of oil if...

Page 42: ...with recommended oil Do not overfill 6 Inspect fuel supply Gaseous fuel lines must have been correctly purged and leak tested in accor dance with applicable fuel gas codes All fuel shut off valves in...

Page 43: ...g through list Note If language was previously programmed this goes directly to Select Hour Use UP and DOWN arrows to select fuel type then press ENTER Fuel Selection NG or LP Follow setup process in...

Page 44: ...g update process the Blue Manual light flashes then the Green Auto light flashes Sequence does this twice When update is complete the unit returns to Install Wizard menu When the controller powers up...

Page 45: ...y AC output and frequency Hertz or Hz at generator MLCB generator disconnect Verify wiring from generator to E1 and E2 lugs at transfer switch 11 Connect AC voltmeter test leads across terminal lugs E...

Page 46: ...ngine will shut down Off Grid Mode ENABLED Proceed as follows to test unit with electrical loads applied when unit is configured to run without a transfer switch and with off grid mode ENABLED 1 Verif...

Page 47: ...eady for automatic operation 3 Verify remote two wire start test switch installed near the Alternative Power Management System is set to ON CLOSED This causes generator to start automatically 4 With g...

Page 48: ...Control Panel Startup Testing 44 Installation Guidelines For 60 Hz EcoGen Generators This page intentionally left blank...

Page 49: ...plug s if necessary Valve clearance out of adjustment Reset valve clearance Engine starts hard and runs rough Air cleaner clogged or damaged Inspect and clean air cleaner Faulty spark plug s Clean in...

Page 50: ...See Cold Smart Start Check controller screen to verify status Unit consumes large amounts of oil Excessive engine oil Adjust oil to correct level Faulty engine breather Contact an IASD for assistance...

Page 51: ...down If startup delay is greater than expected contact an IASD to adjust between 2 to 1500 seconds LOW OIL PRESSURE RED Unit will not start in AUTO with utility loss Check LED s Screen for alarms Chec...

Page 52: ...TTERY PROBLEM YELLOW Yellow LED illuminated in any state Check screen for additional information Contact an IASD CHARGER WARNING YELLOW Yellow LED illuminated in any state Check screen for additional...

Page 53: ...ing protection from rodents and insects by covering the lifting holes located in the base Requires use of the mounting pad shipped with the generator Base Plug Kit Base plugs snap into the lifting hol...

Page 54: ...Accessories 50 Installation Guidelines For 60 Hz EcoGen Generators This page intentionally left blank...

Page 55: ...CONDUIT MAIN AC CONTROL WIRING HOLE FOR 1 1 4 CONDUIT FUEL INLET 1 2 NPT REQUIRED FUEL PRESSURE NATURAL GAS 3 5 7 WATER COLUMN LIQUID PROPANE VAPOR 10 12 WATER COLUMN WIRELESS MODULE BOLTS RECOMMENDED...

Page 56: ...N AREA 1218 48 0 1232 48 5 914 36 0 MINIMUM OPEN AREA 914 36 0 MINIMUM OPEN AREA 914 36 0 MINIMUM OPEN AREA TITLE INSTALL HSB GENERATOR ECOGEN WM AIR OUTLET AIR INTAKE AIR INTAKE TOP VIEW FRONT VIEW R...

Page 57: ...ER INVERTER TWO WIRE START BATTERY VOLTAGE SENSING AC DISTRIBUTION PANEL 120 240V DC DISTRIBUTION PANEL 12V 24V 48V BATTERY 12V 24V 48V INVERTER CHARGER House Loads must be less than 10 kW or 2 hp GEN...

Page 58: ...54 Installation Guidelines For 60 Hz EcoGen Generators Oil Make Up System Schematic OIL MAKE UP SYSTEM SCHEMATIC NOT TO SCALE VENT HOSE ENGINE OUT HOSE ENGINE IN HOSE TO OIL PUMP OIL DIPSTICK AND FIL...

Page 59: ......

Page 60: ...rights reserved Specifications are subject to change without notice No reproduction allowed in any form without prior written consent from Generac Power Systems Inc Generac Power Systems Inc S45 W2929...

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