Generac Power Systems 15 kW EcoGen Owner's Manual

60 hz air cooled generators

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Page 1 Owner’s Manual 60 Hz Air-Cooled Generators 15 kW EcoGen™ 000918 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. (000209a) Register your Generac product at: WWW.GENERAC.COM...
Page 2 Use this page to record important information about your generator set. Record the information found on your unit data label on this page. For the location of the unit data label, see Component Model: Locations. The unit has a label plate affixed to the inside partition, to the left of the control panel console as shown in Component Locations For directions on how to open the...
Page 3: Table Of Contents
Table of Contents Section 1: Safety Rules & General Change Time and Date ........14 Information Programmable Timers ........14 Introduction ............1 Dealer Programmable ..........14 Read This Manual Thoroughly ........1 High Run Speed Timer ........... 14 How to Obtain Service ..........1 USB Port for Firmware Updates .......
Page 4 Section 1: Remove From / To Service Procedure .....27 Remove From Service ..........27 Return to Service ............27 Section 5: Troubleshooting / Diagnostics Engine Troubleshooting ........29 Generator Troubleshooting ......30 G-Flex™ Troubleshooting .........32 G-Flex™ Diagnostics .........34 Section 6: Installation Diagrams Installation Drawing..........35 Off Grid Mode Application Schematic .....36 Oil Make Up System Schematic .......37...
Page 5: Section 1: Safety Rules & General Information Introduction
Safety Rules & General Information Section 1: Safety Rules & General Information Introduction DANGER Thank purchasing this compact, high Indicates a hazardous situation which, if not avoided, performance, air-cooled, engine-driven generator. It is will result in death or serious injury. designed to automatically supply electrical power to operate critical loads during a normal power source (000001)
Page 6: Safety Rules
Safety Rules & General Information Safety Rules WARNING Study these SAFETY RULES carefully before installing, Accidental Start-up. Disconnect the negative battery operating or servicing this equipment. Become familiar cable, then the positive battery cable when working with this Owner’s Manual and with the unit. The on unit.
Page 7: Exhaust Hazards
Safety Rules & General Information WARNING DANGER Risk of injury. Do not operate or service this Electrical backfeed. Use only approved switchgear to machine if not fully alert. Fatigue can impair the isolate generator from the normal power source. ability to service this equipment and could result Failure to do so will result in death, serious injury, and equipment damage.
Page 8: Fire Hazards
Safety Rules & General Information Fire Hazards Explosion Hazards DANGER WARNING Fire hazard. Do not obstruct cooling and ventilating airflow around the generator. Inadequate ventilation could result in fire hazard, possible equipment damage, death or serious injury. (000217) (000192) DANGER WARNING Connection of fuel source must be done by a qualified Fire and explosion.
Page 9: Section 2: General Information
Benefits the unit. If a fault is detected, the unit shuts down and displays an alarm. The 15 kW EcoGen generator brings exciting new technology to the Home Standby generator product. The generator is significantly more fuel-efficient than constant Normal Running speed generators at normal loads, provides premium The engine operates between 2700 RPM–3600 RPM...
Page 10: The Generator
General Information The Generator 001380 Figure 2-1. Component Locations Exhaust Enclosure Data Label Fuel Regulator Oil Dipstick Automatic Voltage Control Pad Battery Compartment Composite Base Regulator (AVR) Engine Air Filter Circuit Breakers Oil Filter AVR Air Filter Fuel Inlet (Back) Oil Tank Owner’s Manual for 60 Hz EcoGen™...
Page 11: Generator
General Information Specifications Generator Model 15 kW EcoGen Rated Voltage Rated Maximum Load 62.5 Current (Amps) at 240 Volts (LP and NG)* Main Circuit Breaker 65 Amp Phase Rated AC Frequency 60 Hz Battery Requirement Group 26R, 12 Volts and 525 CCA Minimum (Generac Part No. 0H3421S) Unit Weight in Lbs.
Page 12: Protection Systems
General Information Protection Systems The generator may have to run for long periods of time System Components with no operator present to monitor the engine/generator - Intake Pipe and Manifold conditions. Therefore, the generator is equipped with a Air Induction - Air Cleaner number of systems to automatically shut down the unit to protect it against potentially damaging conditions.
Page 13: Replacement Parts
General Information Replacement Parts Description 15 kW EcoGen 26R Exide Battery 0H34215 Spark Plug 0G0767A Oil Filter 070185E Air Filter 0J8478 Control Panel Fuse 0D7178T Accessories Performance enhancing accessories are available for air-cooled generators. Accessory Description Cold Weather Kit Recommended in areas where temperatures fall below 32 ºF (0 ºC).
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Page 15: Section 3: Operation
Operation Section 3: Operation Site Prep Verification Main Circuit Breaker (Generator Disconnect) See “A” in Figure 3-1. This is a 2-pole breaker rated It is important that the generator is installed in such a way according to relevant specifications. that the airflow into and out of the generator is not impeded.
Page 16 Operation 3. There are two locks securing the lid, one on each side (A in Figure 3-3). To properly open the lid, press down, on the lid, above the side lock and unlock the latch. 4. Repeat for the other side. If pressure is not applied from the top, the lid may appear stuck.
Page 17: Control Panel Interface
Operation Control Panel Interface Activation The Control Panel Interface is located under the lid of the To receive an activation code, you must have the unit serial enclosure. Before attempting to lift the lid of the number and go to: www.generac.com, “Service & Support” enclosure, verify that both left and right side locks are Tab and then “Activate Your Home Standby”...
Page 18: Using The Auto/Off/Manual Interface Menu
Operation Cold Smart Start The Cold Smart Start feature can be enabled in the EDIT menu. When enabled, the generator will monitor ambient temperature and adjust its warm-up delay based on temperature. If the ambient temperature conditions are below 50 ºF (10 °C) upon startup in AUTO mode, the generator will warm up for 30 seconds allowing the engine to warm before the load is applied.
Page 19: Menu Navigation
Operation Menu Navigation Feature Description System Menus The system returns to the Home screen if the control pad is not used for five minutes. The screen normally displays a Status message, such as Ready to Run (Auto mode) or Switched to OFF (Off mode), and the total Hours of Protection.
Page 20 Operation Switched to “OFF” Hours of Protection 0 (H) ECOGEN HSB MENU MAP Running Manual ENTER SYSTEM DATE/TIME Running-Utility Lost Running-Remote Start Running-2 Wire Start Battery Condition ENTER Switched Off BATTERY SUB MENUS “Good” “Inspect Battery” or “Check Battery” Stopped - Auto Stopped - Alarm ENTER ENTER...
Page 21 Operation Current Date/Time UP ARROW = 02/14/13 07:40 ENTER DOWN ARROW = Run Hours (H) ENTER ENTER MAINT Run Hrs MAINT ENTER Maint. Log Scheduled Access Requires Password DEALER ENTER ENTER - 1 thru 50 + EXAMPLE: "Battery Maintained" Inspect Battery 200 RnHr or 12/27/13 "Schedule A Serviced"...
Page 22: Battery Charger
Operation Battery Charger NOTE: The battery charger is integrated into the control module in all models. The battery charger operates as a Smart Charger that ensures: • Output is continually optimized to promote maximum battery life. • Charging levels are safe. NOTE: A warning is displayed on the LCD when the battery needs service.
Page 23: Automatic Transfer Operation
Operation Automatic Transfer Operation temperature is at or above the fixed temperature, the generator will startup with the normal warm-up delay of To select automatic operation: five seconds. 1. Make sure the transfer switch main contacts are When the generator engine is started, a check for proper set to the normal power source position (loads output voltage build up will be performed.
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Page 25: Section 4: Maintenance
Regular maintenance will improve performance and Service and repairs may be performed by any qualified extend engine/equipment life. Generac Power Systems, service person or repair shop. Inc. recommends that all maintenance work be...
Page 26: Check Enclosure Louvers
Maintenance Maintenance Log Battery inspection and charge check Dates Performed: Oil, oil filter, air filter and spark plug replacement Dates Performed: Valve Adjustment Dates Performed: Check Enclosure Louvers 1. Verify that intake and exhaust louvers and openings are clean and unobstructed. 2.
Page 27: Checking Engine Oil Level
Maintenance Checking Engine Oil Level 8. If the generator was running during a normal power source outage, first turn the main circuit breaker to the ON position. Then, turn ON the needed loads WARNING in the residence. Risk of burns. Allow engine to cool before Engine Oil Recommendations draining oil or coolant.
Page 28: Changing The Oil And Oil Filter
Maintenance Changing the Oil and Oil Filter 001385 Figure 4-3. Exploded View – EcoGen Oil System Drain Pump Kit An Oil System Drain Pump Kit (P/N 0K3717) has been EcoGen Oil System Drain Pump Assembly shipped with this unit. Refer to the instructions included 1.
Page 29: Ecogen Oil Change Procedure
Maintenance EcoGen Oil Change Procedure 8. See Figure 4-8. Insert the ¼ in. hose free end into the unit’s oil tank. WARNING Skin irritation. Avoid prolonged or repeated contact with used motor oil. Used motor oil has been shown to cause skin cancer in laboratory animals.
Page 30: Replacing The Engine Air Filter
Maintenance Replacing the Engine Air Filter Replacing the AVR Filter 1. With the generator shut down, lift the lid and WARNING remove the front panel. Electric shock. AVR maintains electrical 2. See Figure 4-10. Remove the cover clip (A) and charge after generator shutdown.
Page 31: Maintaining The Spark Plugs
Maintenance Maintaining the Spark Plugs Valve Clearance Adjustment Check and replace the spark plugs as necessary. Check the valve clearance after the first 25 hours of operation, then after 500 hour intervals. Adjust if WARNING necessary. Electrical shock. Do not disconnect spark Important: Please contact an Independent Authorized plug wires with engine running.
Page 32: Battery Maintenance
Maintenance 6. Turn the pivot ball stud (B) while checking WARNING clearance between the rocker arm (C) and the valve stem (D) with a feeler gauge. Correct Electrical shock. Disconnect battery ground clearance is in the specification in Section 2 — terminal before working on battery or battery Specifications.
Page 33: Attention After Submersion
Maintenance Attention After Submersion 10. Remove the spark plug(s) and spray a fogging agent into the spark plug(s) threaded openings. If the generator has been submerged in water, it MUST Reinstall and tighten the spark plug(s). NOT be started and operated. Following any submersion 11.
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Page 35: Section 5: Troubleshooting / Diagnostics
Troubleshooting / Diagnostics Section 5: Troubleshooting / Diagnostics Engine Troubleshooting Table 5-1. Engine Troubleshooting Problem Cause Correction Engine will not crank. 1) Fuse blown. 1) Correct short circuit condition by replacing 7.5 Amp fuse. 2) Loose, corroded or defective battery 2) Tighten, clean or replace as necessary.* cables.
Page 36: Generator Troubleshooting
Troubleshooting / Diagnostics Generator Troubleshooting Table 5-2. Generator Troubleshooting Active Alarm Problem Things to Solution Check NONE GREEN Unit running in AUTO but no Check Contact servicing dealer if Generator power in house. Generator Disconnect circuit breaker is in the ON Disconnect position.
Page 37 Troubleshooting / Diagnostics Table 5-2. Generator Troubleshooting (Continued) Active Alarm Problem Things to Solution Check OVERVOLTAGE Unit will not start in AUTO with Check the Contact servicing dealer. 2-wire start signal. LEDs/Screen for alarms. LOW BATTERY YELLOW Yellow LED illuminated in any Check screen Clear alarm.
Page 38: G-Flex™ Troubleshooting
Troubleshooting / Diagnostics G-Flex™ Troubleshooting Table 5-3. G-Flex™ Troubleshooting Ecode/Active Problem Things to Possible Causes/Solution Alarm Check 1048 VSCF Overload RED Unit shuts down Check the Alternator, AVR or wiring is damaged. during operation. LEDs/Screen Contact servicing dealer. for alarms. 1049 VSCF Overload RED Unit shuts down Check the...
Page 39 Troubleshooting / Diagnostics Table 5-3. G-Flex™ Troubleshooting Ecode/Active Problem Things to Possible Causes/Solution Alarm Check 1057 VSCF Unit shuts down Check the Probable causes are: Overvoltage during operation LEDs/Screen 1) The generator has been overloaded. Remove load and or starting. for alarms.
Page 40: G-Flex™ Diagnostics
Troubleshooting / Diagnostics G-Flex™ Diagnostics Table 5-4. G-Flex™ Diagnostics Symptom Possible Causes Generator stalls when large load is Total load is too big for the generator. Loads must be less than 10 kW or 2 hp when supplied. operating under 3600 rpm.Contact installing dealer to correct installation. Output voltage is low/high.
Page 41: Section 6 Installation Diagrams
Installation Diagrams Section 6 Installation Diagrams Installation Drawing Owner’s Manual for 60 Hz EcoGen™ Generator...
Page 42: Off Grid Mode Application Schematic
Installation Diagrams Off Grid Mode Application Schematic Owner’s Manual for 60 Hz EcoGen™ Generator...
Page 43: Oil Make Up System Schematic
Installation Diagrams Oil Make Up System Schematic Owner’s Manual for 60 Hz EcoGen™ Generator...
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Page 48 Part No. 0K6046 Rev. F 12/23/15 Printed in USA Generac Power Systems, Inc. ©2015 Generac Power Systems, Inc. All rights reserved S45 W29290 Hwy. 59 Specifications are subject to change without notice. Waukesha, WI 53189 No reproduction allowed in any form without prior written 1-888-GENERAC (1-888-436-3722) consent from Generac Power Systems, Inc.

Generac Power Systems 15 kW EcoGen Owner's Manual

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