Generac Power Systems EcoGen G0070340 Installation Manuallines Download

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Installation Guidelines for the 60 hz EcoGen™ Generators

iii

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

Read This Manual Thoroughly ....................................1
How to Obtain Service .................................................1

Safety Rules .........................................................2

General Hazards  .........................................................2
Exhaust Hazards  .........................................................3
Electrical Hazards  .......................................................3
Fire Hazards ................................................................4
Explosion Hazards  ......................................................4

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

Before You Begin ........................................................5
Standards Index ..........................................................5

Section 2: Unpacking and Inspection

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

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

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

Intake Side Panel Removal .........................................9

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

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

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

Section 3: Site Selection and Preparation

Site Selection .....................................................11

Installation Guidelines for Stationary Air-Cooled
Generators ................................................................12
Annex A — Explanatory Material ..............................12

Site Preparation .................................................13

Material Sufficient for Level Installation .....................13
Transportation Recommendations ............................14

Placement on Roofs, Platforms, and Other
Supporting Structures .......................................14

Section 4: Generator Placement

Generator Placement .........................................15

Fascia Installation (If Applicable) .....................16

Section 5: Fuel Conversion / Gas

Connections

Fuel Requirements and Recommendations ... 17

Fuel Conversion ................................................ 17

Fuel Consumption ............................................. 18

Fuel Line Sizing ................................................. 18

Natural Gas Pipe Sizing ............................................19
LP Vapor Pipe Sizing ................................................19

Installing and Connecting Gas Lines .............. 20

Shutoff Valve .............................................................20
Flexible Fuel Line ......................................................20
Sediment Trap ...........................................................20

Checking Gas Line Connections ..................... 21

Perform Leak Test ............................................. 21

Natural Gas Vapor Installation (typical) .......... 22

LP Vapor Installation (typical) .......................... 23

Section 6: Electrical Connections

Generator Connections .................................... 25

Control Wiring ................................................... 26

Main AC Wiring .................................................. 27

Service Entrance Decals ................................... 27

Common Alarm Relay (Option) ........................ 28

Automatic Voltage Regulator
(AVR) Cooling Fans ........................................... 28

Battery Requirements ....................................... 28

Battery Installation ............................................ 28

Battery Disposal ................................................ 29

Section 7: Control Panel Start-Up/Testing

Control Panel Interface ..................................... 31

Using the AUTO/MANUAL/OFF Buttons ..................31

Generator Setup ................................................ 31

Activation ...................................................................31

Before Initial Start-up ........................................ 34

Installation Wizard .....................................................34
Interconnect System Self Test Feature .....................34
Before starting, complete the following: ....................34

Electrical Checks ............................................... 36

Generator Tests Under Load ............................ 36

Checking Automatic Operation ........................ 37

Table of Contents

Summary of Contents for EcoGen G0070340

Page 1: ...port 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: ...nt checked periodically by an IASD Normal maintenance service and replacement of parts are the responsibility of the owner operator and 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 conta...

Page 3: ...ascia Installation If Applicable 16 Section 5 Fuel Conversion Gas Connections Fuel Requirements and Recommendations 17 Fuel Conversion 17 Fuel Consumption 18 Fuel Line Sizing 18 Natural Gas Pipe Sizing 19 LP Vapor Pipe Sizing 19 Installing and Connecting Gas Lines 20 Shutoff Valve 20 Flexible Fuel Line 20 Sediment Trap 20 Checking Gas Line Connections 21 Perform Leak Test 21 Natural Gas Vapor Inst...

Page 4: ...rn the generator OFF 37 To turn the generator back ON 37 Section 8 Troubleshooting Engine Troubleshooting 39 Generator Troubleshooting and System Diagnosis 40 AVR Troubleshooting 42 Section 9 Accessories Section 10 Diagrams IInstallation Drawing 10000002491 1 of 2 47 Installation Drawing 10000002487 2 of 2 48 Off Grid Mode Application Schematic 49 Oil Make Up System Schematic 50 ...

Page 5: ...l must be used in conjunction with the appropriate owner s manual SAVE THESE INSTRUCTIONS The manufacturer suggests that this manual and the rules for safe operation be copied and posted near the unit installation site Safety should be stressed to all operators and potential operators of this equipment Throughout this publication and on tags and decals affixed to the generator DANGER WARNING and C...

Page 6: ...trocution Potentially lethal voltages are generated by this equipment Render the equipment safe before attempting repairs or maintenance Failure to do so could result in death or serious injury 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 000130 WARNING Accidental Start up Di...

Page 7: ... or damage to the generator 000178a Asphyxiation Always use a battery operated carbon monoxide alarm indoors and installed according to the manufacturer s instructions Failure to do so could result in death or serious injury WARNING 000144 DANGER Electrocution Contact with bare wires terminals and connections while generator is running will result in death or serious injury 000150 DANGER Electrocu...

Page 8: ...c standby generators 000100a WARNING Consult Manual Read and understand manual completely before using product Failure to completely understand manual and product could result in death or serious injury WARNING to use required safety equipment could result in death or serious injury 000257 Electrocution Refer to local codes and standards for safety equipment required when working with a live elect...

Page 9: ...ns pertaining to the installation 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 ...

Page 10: ... ICC IFGC This list is not all inclusive Check with the Authority Having Local Jurisdiction AHJ for any local codes or standards which may be applicable to your jurisdiction The above listed standards are available from the following internet sources www nfpa org www iccsafe org www rerc org Rural Electricity Resource Council P O Box 309 Wilmington OH 45177 0309 www asabe org American Society of A...

Page 11: ... damage If a loss or damage is noted after delivery separate the damaged 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 f...

Page 12: ... A in Figure 2 4 Press down on the lid above the side lock and unlock the latch to properly open the lid 4 Repeat for the other side The lid may appear stuck if pressure is not applied from the top NOTE Always verify that the side locks are unlocked before attempting to lift the lid 5 Remove the front access panel by lifting it straight up and out once the lid is open NOTE Always lift the front ac...

Page 13: ...fting up D Figure 2 5 Intake Side Panel Removal 1 Perform a visual inspection for any hidden freight damage Contact the freight carrier if damage is present 2 See Figure 2 6 and Figure 2 7 for customer connections and loose parts location Figure 2 9 illustrates parts shipped loose Figure 2 6 Customer Connection Area and Loose Parts Location Rear Connections Figure 2 7 Rear Connections A B D C A Cu...

Page 14: ...rough both lock tabs B NOTE DO NOT leave the breaker disconnect locked in the open OFF position during normal generator operation Leaving the breaker in the open position will prevent the transfer of power to the generator from the transfer equipment during normal generator operation Parts Shipped Loose Figure 2 9 Parts Shipped Loose B A A Keys B Flexible fuel line C Battery terminal cap D Rubber ...

Page 15: ...nce per NFPA testing labeling and listing unless state or local codes dictate otherwise D Windows and openings No operable windows doors or openings in the wall are permitted within 5 ft 1 52 m from any point of the generator E Existing wall One hour fire rated walls allow closer placement of the generator set Confirm before installation F Removable fence Removable fence panels for servicing canno...

Page 16: ... to the connected loads REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE AND LOCATION The generator must be installed on a level sur face The generator must be level within a 0 5 in 13 mm all around The generator is typically placed on pea gravel compacted soil crushed stone or a concrete pad Check local codes to see what type is required If a concrete pad is required all appli cable codes sh...

Page 17: ...nected loads and fuel supply Leave adequate room around the area for service access check local code and place high enough to keep rising water from reaching the generator Choose an open space that will provide adequate and unobstructed airflow Place the unit so air vents won t become clogged with leaves grass snow or debris Verify that exhaust fumes will not enter any building through eaves windo...

Page 18: ...etal Placement on Roofs Platforms and Other Supporting Structures Where required to place the generator on a roof platform or other supporting structure like a deck the generator shall be placed in accordance with the requirements in NFPA 37 Section 4 1 3 The generator can be located 18 in 45 7 cm from structures having combustible walls and 5 ft 1 52 m from any operable opening in the structure T...

Page 19: ...d be followed Place the generator with the DTD pad attached and position correctly as per the dimensional information given in Site Preparation NOTE Generator must be level within 0 5 in 13 mm NOTE See Figure 4 2 DO NOT remove the DTD pad for mounting the generator to concrete The pad is pre drilled to accommodate mounting bolts Figure 4 1 DTD Composite Pad See Figure 4 2 Four mounting points are ...

Page 20: ...f the fascia two each opposite one another A Once the mounts are installed snap one of the end pieces into one of the front rear pieces of fascia Repeat this action with the other two remaining pieces of fascia NOTE Do not assemble all four pieces together at this point B Place both assemblies at the base of the generator and fit the rubber mounts into the lifting holes in the generator base C Onc...

Page 21: ... specification once the generator is installed See the NFPA website at www nfpa org for further information regarding NFPA requirements 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 shrubs and other landscaping Piping strength and connections should b...

Page 22: ...essure system Generator Natural Gas Propane 1 2 Load Full Load 1 2 Load Full Load 15 kw EcoGen 4 25 150 8 16 288 1 48 5 62 54 00 2 86 10 82 104 00 Natural gas is in m3 h ft3 h Propane is in gal h l h LP ft3 h LPV Values given are approximate These are approximate values Use the appropriate spec sheet or owner s manual for specific values Verify that gas meter is capable of providing enough fuel fl...

Page 23: ...he right The number to the right is the maximum length measured in meters feet allowed for the pipe sizes on top The pipe sizes are measured by inside diameter ID to include any fittings valves must be full flow elbows tees or angles Add 2 5 ft 0 76 m per any bend tee or angle in the pipe to the overall distance NOTE Pipe sizes are using a second stage regulator NOTE The minimum LP tank size is 25...

Page 24: ...54 1 ball valve part number 0K8184 1 1 4 ball valve part number 0L2844 1 1 2 ball valve part number 0L2845 2 ball valve part number 0L2846 Flexible Fuel Line When connecting the gas line to the generator use a listed assembly that meets the requirements of ANSI Z21 75 CSA 6 27 Connectors for Outdoor Gas Appliances and Manufactured Homes or AGA approved flexible fuel line in accordance with local r...

Page 25: ...hen completed but keep manometer connected for future tests of the generator while starting running and under loads Figure 5 4 Checking Pressure with Manometer Perform Leak Test All products are tested at the factory before shipping to ensure the performance and integrity of the fuel system However it is important to perform a final fuel system leak test before starting the generator The entire fu...

Page 26: ...7 26 A BTU and pressure decal B Minimum distance from rear obstruction see Site Selection C Manual shutoff valve pressure port optional D Pipe nipple field supplied E Flexible fuel line F Check distance with gas provider G Clamp H Reinforcing rod J Size gas meter for 100 generator load plus all appliance loads K For underground installations verify piping system for code compliance L Gas main F B ...

Page 27: ...ressure regulator M Fuel tank sized large enough to provide required BTUs for generator and ALL connected appliance loads Be sure to correct for weather evaporation LP BTU ft3 h X 2500 Megajoules m3 h X 93 15 A BTU and pressure decal B Minimum distance from rear obstruction C Manual shutoff valve pressure port optional D Pipe nipple field supplied E Flexible fuel line F Check distance with gas pro...

Page 28: ...Fuel Conversion Gas Connections 24 Installation Guidelines For 60 Hz EcoGen Generators This page intentionally left blank ...

Page 29: ... generator for wiring connection details Recommended wire gauge sizes for this wiring depends on the length of the wire as recommended in Table 6 3 Exception Conductors of AC and DC circuits rated 1000 volts nominal or less shall be permitted to occupy the same equipment cable or conduit All conductors shall have an insulation rating equal to at least the maximum circuit voltage applied to any con...

Page 30: ...stud J Neutral bar C1 Wire tie for control wires E1 Power lug E1 G Ground lug Table 6 2 Customer Wiring Connections Terminal Numbering Decal Wire Numbers YELLOW NO 1 NO 2 N1 N2 240 VAC 240 VAC for Cold Weather Kit if required from a dedicated 2 Pole 15A Breaker BLUE NO 3 T1 Fused 120 VAC for battery charger from a 1 Pole 15A Breaker BLACK NO 3 0 DC Common ground wire RED NO 4 194 DC 12 VDC for tra...

Page 31: ...urce in a separately derived system The installation must be made in accordance with NEC Articles 250 30 and 250 35 A if the generator will be installed as a separately derived system NOTE Torque all wiring lugs bus bars and connection points to the proper torque specifications Conductors of AC and DC circuits rated 1000 volts nominal or less shall be permitted to occupy the same equipment cable o...

Page 32: ...m or Group 35AGM 650CCA minimum Battery Installation Group 26R batteries only Fill the battery with the proper electrolyte fluid if necessary Fully charge the battery before installing it Before installing and connecting the battery complete the following steps 1 Verify that the generator is OFF 2 Disengage all connected loads 3 Remove the 7 5A fuse from the generator control panel Battery cables ...

Page 33: ...eries Battery Disposal Always recycle 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 WARNING Environmental Hazard Always recycle batteries at an official ...

Page 34: ...Electrical Connections 30 Installation Guidelines For 60 Hz EcoGen Generators This page intentionally left blank ...

Page 35: ...t has already been powered up it is necessary to disconnect the generator battery fuse and battery charge circuit T1 2 The installation wizard prompts the user to set the fuel type Chose fuel type and press ENTER The controller will display Activate me ENT or ESC Press ESC to run in MANUAL 3 Press ENTER and use the up down arrow keys and the ENTER key to input the activation code NOTE If you push ...

Page 36: ...ng the EDIT menu Press ENTER to begin the activation process If ESCAPE is pressed instead of ENTER the generator will only run in manual mode for test purposes and NOT ACTIVATED will be displayed You will need to remove the 7 5 amp generator control panel fuse AND disconnect the T1 N1 and N2 connector in the external connection box if equipped or disengage all connected loads If you do not have yo...

Page 37: ...ve and your screen shows this display Follow the controller prompts to continue setting the time function Refer to your Owner s Manual with questions What happens if Wrong Passcode Try Again appears Re enter the activation code If a second attempt is unsuccessful check the number against the code given on activategen com If it is correct and the generator will not accept it contact 1 888 9ACTIVATE...

Page 38: ... controller must be removed to clear this warning Voltage must be present at the N1 and N2 terminals inside the generator control panel for this test to be performed and pass NOTE All appropriate panels must be in place during any operation of the generator This includes operation by a servicing technician while conducting troubleshooting procedures Before starting complete the following 1 Verify ...

Page 39: ...Select Hour 0 23 14 Select Min 0 59 0 ENTER ENTER Select Month 1 12 2 ENTER Select Date 1 31 13 ENTER Select Year 0 99 13 ENTER FIRMWARE V 1 01 HARDWARE V 1 05 Holding the Up or Down arrow button for 2 seconds will speed dial through the selections Defaults to English if not selected Note If language was previously programmed this goes directly to Select Hour Use UP and DOWN arrows to select fuel ...

Page 40: ... even if the 7 5 amp ATO fuse is removed To avoid hand injury always exercise caution when working near the AVR fan housing Generator Tests Under Load 1 Test the generator with electrical loads applied Start by placing all of the 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 Alternat...

Page 41: ...ing utility outages Shutdowns may be required during outages to perform routine maintenance or to conserve fuel To turn the generator OFF Turn the generator off before performing any maintenance This is to prevent accidental startup 1 Turn the main utility disconnect OFF OPEN 2 Lift lid and turn the MLCB generator disconnect on the generator to OFF OPEN 3 Allow generator to run and cool down for o...

Page 42: ...Control Panel Start Up Testing 38 Installation Guidelines For 60 Hz EcoGen Generators This page intentionally left blank ...

Page 43: ... 1 Air cleaner plugged or damaged 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 ...

Page 44: ...CT BATTERY YELLOW Yellow LED illumi nated in any state Check the screen for addi tional informa tion Inspect battery Press ENTER to clear LOW BATTERY YELLOW Yellow LED illumi nated in any state Check the screen for addi tional informa tion Clear alarm Using the control panel check the battery by navigating to the BATTERY MENU option from the MAIN MENU If battery condition displays GOOD contact an ...

Page 45: ...in AUTO with remote two wire start set to the ON CLOSED posi tion Check the LED s screen for alarms Contact Independent Authorized Servicing Dealer RPM SENSE LOSS RED Unit was running and shuts down attempts to restart Check the LEDs Screen for alarms Clear alarm and remove loads from the generator Put back in AUTO and restart If problem returns contact Independent Authorized Servicing Dealer to i...

Page 46: ... Check the LEDs Screen for alarms 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 o...

Page 47: ...e RED 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 V...

Page 48: ... running 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 AVR Troubleshooting Co...

Page 49: ...endations Auxiliary Transfer Switch Lockout Enables any of the transfer switches to completely lock out one large electrical load by tying into its control system Fascia Base Wrap The fascia base wrap snaps together around the bottom of the generator This offers a sleek contoured appearance as well as offering protection from rodents reptiles and insects by covering the lifting holes located in th...

Page 50: ...Accessories 46 Installation Guidelines For 60 Hz EcoGen Generators This page intentionally left blank ...

Page 51: ...002491 1 of 2 914 36 0 MINIMUM OPEN AREA ON SIDES AND FRONT 457 2 18 0 1218 0 48 0 1232 0 48 5 76 2 3 0 PEA GRAVEL MINIMUM DO NOT LIFT BY ROOF ALL DIMENSIONS IN MILLIMETERS INCHES AIR INTAKE AIR INTAKE FRONT VIEW RIGHT SIDE VIEW AIR OUTLET TOP VIEW 30 2 1 2 LIFTING HOLES 4 CORNERS RIGHT VIEW INTAKE PANEL REMOVED ...

Page 52: ...IRED FUEL PRESSURE NATURAL GAS 3 5 7 WATER COLUMN LIQUID PROPANE VAPOR 10 12 WATER COLUMN MAIN AC CONTROL WIRING HOLE FOR 3 4 CONDUIT MAIN AC CONTROL WIRING HOLE FOR 1 1 4 CONDUIT LEFT SIDE VIEW 456 6 18 0 1154 0 45 4 536 8 21 1 392 7 15 5 68 0 2 7 340 7 13 4 MOUNTING TO CONCRETE PAD 10 0 3 8 DIA CLEARANCE HOLE 4 PLACES 3 8 DIA MASONRY ANCHOR BOLTS RECOMMENDED A CONCRETE PAD OPTIONAL MOUNTING TO H...

Page 53: ...ATTERY 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 APPLICATI...

Page 54: ...n 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 COOLER IN HOSE COOLER OUT HOSE OIL DIPSTICK AND FILL 001478 ...

Page 55: ......

Page 56: ...ghts 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 www generac com ...

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