Generac Power Systems ecoGen G0061030 Installation Manuallines Download Page 1

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Installation Guidelines

60 Hz Air–Cooled Generators

15 kW EcoGen™

SAVE THIS MANUAL FOR FUTURE REFERENCE

000918

Para español , visita:

http://www.generac.com/service–support/product–support–lookup

Pour le français, visiter :

http://www.generac.com/service–support/product–support–lookup

(000209a)

WARNING

This product is not intended to be used in
a critical life support application. Failure to
adhere to this warning could result in
death or serious injury.

WWW.GENERAC.COM

1–888–GENERAC

(888–436–3722)

Summary of Contents for ecoGen G0061030

Page 1: ...support product support lookup Pour le français visiter http www generac com service support product support lookup 000209a WARNING This product is not intended to be used in a critical life support application Failure to adhere to this warning could result in death or serious injury Register your Generac product at WWW GENERAC COM 1 888 GENERAC 888 436 3722 ...

Page 2: ...mal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage may contribute to the need for additional maintenance or service When the generator requires servicing or repairs Generac recommends contacting an Independent Authorize...

Page 3: ...nts and Recommendations 17 Fuel Conversion 17 Fuel Consumption 18 Fuel Line Sizing 18 Natural Gas Pipe Sizing 18 LP Vapor Pipe Sizing 19 Pipe Sizing Summary 19 Installing and Connecting Gas Lines 19 Shutoff Valve 19 Flexible Fuel Line 20 Sediment Trap 20 Checking Gas Line Connections 20 Natural Gas Vapor Installation typical 21 LP Vapor Installation typical 22 Section 6 Electrical Connections Gene...

Page 4: ... 34 Generator Tests Under Load 34 Checking Automatic Operation 34 Installation Summary 35 Shutting Generator Down While Under Load 35 Section 8 Troubleshooting Engine Troubleshooting 37 Generator Troubleshooting 38 G Flex Troubleshooting 39 Section 9 Accessories Section 10 Diagrams Installation Drawing 1 of 2 45 Installation Drawing 2 of 2 46 Off Grid Mode Application Schematic 47 Oil Make Up Syst...

Page 5: ... Throughout this publication and on tags and decals affixed to the generator DANGER WARNING and CAUTION blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly Observe them carefully Their definitions are as follows NOTE Notes provide additional information important to a procedure or component These safet...

Page 6: ...d result in death or serious injury WARNING This unit is not intended for use as a prime power source It is intended for use as an intermediate power supply in the event of temporary power outage only See individual unit specifications for required maintenance and run times pertaining to use 000247 000187 WARNING 000130 WARNING Accidental Start up Disconnect the negative battery cable then the pos...

Page 7: ... Electrical backfeed Use only approved switchgear to isolate generator from the normal power source Failure to do so will result in death serious injury and equipment damage 000152 DANGER Electrocution Verify electrical system is properly grounded before applying power Failure to do so will result in death or serious injury 000188 DANGER Electrocution Do not wear jewelry while working on this equi...

Page 8: ...t must be positioned in a manner that prevents combustible material accumulation underneath Failure to do so could result in death or serious injury 000192 DANGER 000151 DANGER Connection of fuel source must be done by a qualified professional technician or contractor Incorrect installation of this unit will result in death serious injury and damage to equipment and property damage 000174 DANGER R...

Page 9: ... of this engine generator power system Use the most current version of applicable codes or standards relevant to the local jurisdiction generator used and installation site NOTE Not all codes apply to all products and this list is not all inclusive In the absence of pertinent local laws and standards the following publications may be used as a guide these apply to localities which recognize NFPA a...

Page 10: ...Safety Rules General Information 6 Installation Guidelines for 60 Hz EcoGen Generator This page is intentionally left blank ...

Page 11: ... materials and contact the carrier for claim procedures Concealed damage is understood to mean damage to the contents of a package that is not evident at the time of delivery but is discovered later Required Tools General SAE and Metric hand tools Wrenches Sockets Screwdrivers Standard electrician s hand tools Drill and bits for mounting and routing conduits 4mm Allen wrench for access to customer...

Page 12: ...n the lid press down on the lid above the side lock and unlock the latch 8 Repeat for the other side If pressure is not applied from the top the lid may appear stuck NOTE Always verify that the side locks are unlocked before attempting to lift the lid 9 Once the lid is open remove the front access panel by lifting it up and out NOTE Always the lift the front access panel up before pulling away fro...

Page 13: ... Connection Area and Loose Parts Location Figure 2 7 Rear of Generator Figure 2 7 illustrates the following 001374 A Customer connection area underneath and behind the control panel B Fuel regulator C Battery compartment D Positive and Negative Battery Cables E Location of Parts Shipped Loose 001375 A B C E D 001376 A C B D A Main AC Control Wiring hole for 3 4 inch conduit B Main AC Control Wirin...

Page 14: ... the battery wires or the alternator can Figure 2 8 Parts Shipped Loose A Keys B Battery Terminal Cap C Main Line Circuit Breaker MLCB Terminal Caps D Wire Shielding to separate AC from DC control wires E Main Line Circuit Breaker MLCB Locking Mechanism F Flexible Fuel Line G Rubber Mounts only for units that include fascia H Rear Mounting Brackets 2 I Oil Drain Pump Kit J Installation and Owner s...

Page 15: ...This includes shrubs bushes and trees Clearance from the back of the generator must be a minimum of 18 in 457 mm Clearance at 000607 No operable windows or openings in the wall permitted within 1 52 m 5 ft from any point of the generator Top of Generator 3 ft 0 91 m 5 ft 1 52 m Existing Wall 18 in 457 mm Minimum Distance 5 ft 1 52 m Minimum Distance 5 ft 1 52 m Minimum Distance These guidelines ar...

Page 16: ...rovided that are installed outdoors shall be located at least 5 ft 1 52 m from openings in walls and at least 5 ft 1 52 m from structures having combustible walls A minimum separation shall not be required where the following conditions exist 1 The adjacent wall of the structure has a fire resis tance rating of at least one hour 2 The weatherproof enclosure is constructed of noncombustible materia...

Page 17: ...ite Selection Select the type of base such as but not limited to gravel or concrete as desired or as required by local laws or codes Verify your local requirements before selecting Material Sufficient for Level Installation See Figure 3 3 Dig a rectangular area approximately 5 in 127 mm deep A and about 6 in 152 mm longer and wider B than the footprint of the generator Fill with 4 in 102 mm of pea...

Page 18: ...Site Selection and Preparation 14 Installation Guidelines for 60 Hz EcoGen Generator This page intentionally left blank ...

Page 19: ...the inside front of the enclosure and two outside rear mounting brackets NOTE Use the template at the top of the generator carton to mark the concrete pad for drilling of the two front mounting holes For dimensions of the two rear mounting holes see Installation Drawing 2 of 2 DO NOT USE brackets from shipping pallet Use stainless steel brackets provided with loose parts Figure 4 2 Mounting Hole L...

Page 20: ...Generator Placement 16 Installation Guidelines for 60 Hz EcoGen Generator This page intentionally left blank ...

Page 21: ...applications Once the generator is installed verify fuel pressure NEVER drops below the required specification For further information regarding NFPA requirements refer to the NFPA website at www nfpa org Always consult local fuel suppliers or the fire marshal to check codes and regulations for proper installation Local codes will mandate correct routing of gaseous fuel line piping around gardens ...

Page 22: ...n top Pipe sizes are measured by inside diameter ID to include any fittings valves must be full flow elbows tees or angles Generator Natural Gas LP Vapor 1 2 Load Full Load 1 2 Load Full Load 15 kW EcoGen 128 3 63 302 8 55 1 28 4 85 47 61 2 62 9 92 104 4 Natural gas is in ft3 h m3 h LP is in gal h l h ft3 h Values given are approximate These are approximate values Use the appropriate spec sheet or...

Page 23: ...rer s specifications for sizing and installation information Installing and Connecting Gas Lines Both natural gas and LP Vapor are highly volatile substances so strict adherence to all safety procedures codes standards and regulations is essential Gas line connections should be made by a certified plumber familiar with local codes Always use AGA approved gas pipe and a quality pipe sealant or join...

Page 24: ...trap as illustrated Figure 5 4 Sediment Trap Checking Gas Line Connections 1 Check for leaks by spraying all connection points with a non corrosive gas leak detection fluid You should not see the solution be blown away or form bubbles 2 Check gas pressure at the regulator in the generator by following these steps Close gas supply valve See Figure 5 5 Remove the top gas pressure test port from the ...

Page 25: ...lation typical 000618a NG BTU ft3 h X 1000 Megajoules m3 h X 37 26 A BTU and Pressure Decal B Check Distance with Gas Provider C Accessory Valve with Manometer Port D Size Gas Meter for Generator Load Plus All Appliance Loads E Flexible Fuel Line F Sediment Trap G For Underground Installations Verify Piping System for Code Compliance H Gas Main B C A D E F G H ...

Page 26: ...ajoules m3 h X 93 15 A BTU and Pressure Decal B Check Distance with Gas Provider C Primary Fuel Pressure Regulator Per LP Provider D Manual Shutoff Valve E Secondary Fuel Pressure Regulator F Flexible Fuel Line G Sediment Trap H Accessory Valve with Manometer Port I Size fuel tank large enough to provide required BTUs for generator and ALL connected appliance loads Be sure to correct for weather e...

Page 27: ...nly bare wire NOTE The system is equipped with a 2 wire start to facilitate connection to the inverter system Control Wiring Figure 6 1 Control Wiring Connections Table 6 1 Control Pad Connections Wire Color Terminal Wire Wire Description Blue T1 120 VAC for Battery Charger Single Pole 15 Amp Breaker see Control Wiring Notes Black 0 DC Common Ground Wire Yellow N1 240 VAC for Cold Weather Kit Util...

Page 28: ...e opening in the back cover and into the bottom lug Torque to the proper specification Figure 6 3 Inserting Power Wire E1 or E2 5 There are three screws inside the top of the breaker panel behind the breaker door Removing these screws will allow the entire breaker box to be carefully pulled out When reinstalling be certain that the tabs on the bottom lock into place 6 Connect the Neutral wire to t...

Page 29: ... follows 4 Connect the red battery cable from starter contactor to the battery post indicated by a positive POS or 5 Connect the black battery cable from frame ground to the battery post indicated by a negative NEG or 6 Install the red battery post cover included NOTE Dielectric grease should be used on battery posts to aid in the prevention of corrosion NOTE Damage will result if battery connecti...

Page 30: ... batteries 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 battery recycling visit the Battery Council International website at http batterycouncil org ...

Page 31: ...always set the control pad to OFF and remove the 7 5 amp fuse before working on or around the generator or the electrical loads that are to be powered by the generator For added security place a DO NOT OPERATE tag or placard at the control pad and the electrical loads that are to be powered by the generator Never run the generator with any access panel removed Using the AUTO MANUAL OFF Buttons Fig...

Page 32: ...put generator settings The Installation Wizard will start every time AC and DC power is removed and re applied to the generator Figure 7 4 Installation Wizard Menu 000135 CAUTION Engine damage Verify proper type and quantity of engine oil prior to starting engine Failure to do so could result in engine damage SAE 30 10W 30 Synthetic 5W 30 000399 000135 CAUTION Engine damage Verify proper type and ...

Page 33: ...Control Panel Start Up Testing Installation Guidelines for 60 Hz EcoGen Generator 29 This page intentionally left blank ...

Page 34: ... calling 1 888 9ACTIVATE 1 888 922 8482 Activating the generator is a simple one time process that is guided by the controller screen prompts Once the product is activated the controller screen will not prompt you to activate again even if you disconnect the generator battery fuse and battery charge circuit T1 60 Hz T1 T2 50 Hz After obtaining your activation code please complete the following ste...

Page 35: ...ature Upon power up this controller will go through a system self test which will check for the presence of normal power source voltage on the DC circuits This is done to prevent damage if the installer mistakenly connects AC normal power source sensing wires into the DC terminal block If normal power source voltage is detected the controller will display a warning message and lock out the generat...

Page 36: ...1 thru 50 Warning Message s Low Battery FIRMWARE ERROR 9 Fuel Pressure Battery Problem Charger Warning Charger Missing AC Overload Warning Overload Cooldown SEEPROM ABUSE USB Warning Download Failure Running Manual Running Utility Lost Running Remote Start Running 2 Wire Start Switched Off Stopped Auto Stopped Alarm Alarm Message s High Engine Temp Low Oil Pressure Overcrank Overspeed RPM Sense Lo...

Page 37: ...rrent V XXXX USB V XXXX Are You Sure Yes or No ESC ENTER ESC ENTER ESC ENTER Select Yes then Press Enter to continue or Press ESCAPE to escape out of updating During 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 the very first screen displays the v...

Page 38: ...e breakers on the Alternative Power Management System into the OFF Open position 2 Switch the recommended disconnect switch installed at the generator input to the Alternative Power Management System to OFF Open position 3 Place the main Circuit Breaker on the generator in the ON Closed position 4 Press MANUAL on the control pad The generator should crank and start immediately Allow the engine to ...

Page 39: ...hile Under Load IMPORTANT NOTE To turn the generator off during main power source outages to perform maintenance or conserve fuel follow these steps To turn the generator OFF while running in AUTO and online 1 Turn the main power source disconnect OFF 2 Turn the main line circuit breaker MLCB on the generator to OFF OPEN 3 Turn the generator OFF To turn the generator back ON 1 Put the generator ba...

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Page 41: ...aged 2 Defective spark plug s 3 Fuel regulator not set 4 Fuel pressure incorrect 5 Fuel selector in wrong position 1 Check replace air cleaner 2 Clean check gap or replace plug s 3 Set fuel regulator 4 Confirm fuel pressure to regulator is 10 12 in water column 19 22 mm mercury for LP and 3 5 7 in water column 7 13 mm mercury for natural gas 5 Move selector to correct position Generator is set to ...

Page 42: ...RESSURE RED Unit will not start in AUTO with 2 wire start signal Check the LEDs Screen for alarms Check oil level Add oil per Owner s Manual Contact Independent Authorized Servicing Dealer if oil level is correct RPM SENSE LOSS RED Unit will not start in AUTO with 2 wire start signal Check the LEDs Screen for alarms Clear alarm Navigate to the BATTERY MENU on the control pad LCD Contact Independen...

Page 43: ...larms Voltage supply to the AVR is high If an external battery charger is in use contact installing dealer to correct installation If an external battery charger is NOT in use contact Independent Authorized Servicing Dealer 1052 VSCF DC Overvoltage RED Unit shuts down during operation Check the LEDs Screen for alarms Probable causes are 1 The generator was temporarily overloaded 2 The output was t...

Page 44: ...ED Unit shuts down during operation or starting Check the LEDs Screen for alarms The DPE winding supplies this voltage 1 Alternator damage Contact Independent Authorized Servicing Dealer 1059 VSCF Field Loss RED Unit shuts down during starting Check the LEDs Screen for alarms Unit detects no output voltage while starting 1 Alternator damage Contact Independent Authorized Servicing Dealer 1061 VSCF...

Page 45: ...nning in AUTO it will continue to run for one hour to cool electronics without fan Check the LEDs Screen for alarms Small fan current incorrect Probable causes are 1 Fan wiring or mechanical problem Contact Independent Authorized Servicing Dealer 2 Air path is blocked Check AVR filter KEEP FINGERS AWAY FROM FAN HOUSING PERSONAL INJURY CAN OCCUR IF FAN IS RUNNING Table 8 3 G Flex Troubleshooting Co...

Page 46: ...Troubleshooting 42 Installation Guidelines for 60 Hz EcoGen Generator This page intentionally left blank ...

Page 47: ...us maintenance schedule event history and much more This portal is accessible via computer tablet or smart phone Sends emails and or text notifications the moment there is any change in the generator s status Notification settings can be customized to what type of alert is sent and how often For more information visit www MobileLinkGen com Touch Up Paint Kit Very important to maintain the look and...

Page 48: ...Accessories 44 Installation Guidelines for 60 Hz EcoGen Generator This page intentionally left blank ...

Page 49: ...0 76 2 3 0 PEA GRAVEL PEA GRAVEL MINIMUM MINIMUM 1229 5 1229 5 48 4 48 4 1226 1226 48 3 48 3 732 5 732 5 28 8 28 8 637 6 637 6 25 1 25 1 642 642 25 3 25 3 LEFT SIDE VIEW LEFT SIDE VIEW DO NOT LIFT BY ROOF DO NOT LIFT BY ROOF FRONT VIEW FRONT VIEW 30 2 30 2 1 2 1 2 LIFTING HOLES 4 CORNERS LIFTING HOLES 4 CORNERS 001476a ...

Page 50: ...ES 3 8 DIA MASONRY ANCHOR 3 8 DIA MASONRY ANCHOR BOLTS RECOMMENDED BOLTS RECOMMENDED AIR INTAKE AIR INTAKE AIR OUTLET AIR OUTLET AIR INTAKE AIR INTAKE MAIN AC CONTROL WIRING HOLE FOR 3 4 CONDUIT MAIN AC CONTROL WIRING HOLE FOR 3 4 CONDUIT RIGHT SIDE VIEW RIGHT SIDE VIEW FRONT OF UNIT FRONT OF UNIT 10 0 3 8 DIA CLEARANCE 10 0 3 8 DIA CLEARANCE HOLE 2 PLACES HOLE 2 PLACES 3 8 DIA MASONRY ANCHOR 3 8 ...

Page 51: ...TTERY CHARGER 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 GENERATOR HOUSE HOUSE LOADS 120V 240V CHARGER SUPPLY TWO WIRE START TWO WIRE START 24 48V DC 12 24 36 48V DC WIND TURBINE PHOTO VOLTAIC PANEL 120 240V OUTPUT ECOGEN TYPICAL OFF GRID APPLICATIO...

Page 52: ...on Guidelines for 60 Hz EcoGen Generator Oil Make Up System Schematic OIL MAKE UP SYSTEM SCHEMATIC NOT TO SCALE VENT HOSE ENGINE OUT HOSE ENGINE IN HOSE TO OIL PUMP COOLER IN HOSE COOLER OUT HOSE OIL DIPSTICK AND FILL 001478 ...

Page 53: ...Diagrams Installation Guidelines for 60 Hz EcoGen Generator 49 This page intentionally left blank ...

Page 54: ...Diagrams 50 Installation Guidelines for 60 Hz EcoGen Generator This page intentionally left blank ...

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Page 56: ...nc All 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 W29290 Hwy 59 Waukesha WI 53189 1 888 GENERAC 1 888 436 3722 generac com ...

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