Generac Power Systems 15 kw ecogen Installation Manuallines
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Generac Power Systems 15 kw ecogen Installation Manuallines

60 hz air-cooled generators
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Installation Guidelines

60 Hz Air–Cooled Generators
15 kW EcoGen™
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)
000918
WARNING
(000209a)

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Summary of Contents for Generac Power Systems 15 kw ecogen

  • Page 1: Installation Guidelines

    Installation Guidelines 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 your Model: Owner’s Manual. The unit has a label plate affixed to the inside partition, to the left of the control panel console.

  • Page 3: Table Of Contents

    Table of Contents Section 1: Safety Rules & General Fuel Line Sizing ..........18 Information Natural Gas Pipe Sizing ..........18 LP Vapor Pipe Sizing ..........19 Introduction ............1 Pipe Sizing Summary ........19 Read This Manual Thoroughly ........1 How to Obtain Service ..........1 Installing and Connecting Gas Lines ....
  • Page 4 Table of Contents Interconnect System Self Test Feature ...31 Before starting, complete the following: ....31 Check Manual Transfer Switch Operation ..31 Electrical Checks ..........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...

  • Page 5: Section 1: Safety Rules & General Information Introduction

    Safety Rules & General Information Section 1: Safety Rules & General Information Introduction instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe Thank purchasing this compact, high- them carefully. Their definitions are as follows: performance, variable speed, air-cooled, engine-driven stationary automatic standby generator set.

  • 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 Installation Manual, the Owner’s Manual, and on unit.

  • Page 7: Exhaust Hazards

    Safety Rules & General Information WARNING DANGER Injury and equipment damage. Do not use Electrocution. Verify electrical system is generator as a step. Doing so could result in falling, properly grounded before applying power. damaged parts, unsafe equipment operation, Failure to do so will result in death or serious and could result in death or serious injury.

  • Page 8: Explosion Hazards

    Safety Rules & General Information General Rules WARNING Risk of electrocution. Refer to NFPA 70E for DANGER safety equipment required when working with with a live electrical system. Failure to use Loss of life. Property damage. Installation must always required safety equipment could result in comply with applicable codes, standards, laws and death or serious injury.

  • Page 9: Before You Begin

    Safety Rules & General Information Before You Begin 1. National Fire Protection Association (NFPA) 70: The NATIONAL ELECTRIC CODE (NEC) * • Contact the local inspector or City Hall to be aware of 2. NFPA 10: Standard for Portable Fire Extinguishers * all federal, state and local codes that could impact the installation.
  • Page 10 Safety Rules & General Information This page is intentionally left blank. Installation Guidelines for 60 Hz EcoGen™ Generator...

  • Page 11: Section 2: Unpacking And Inspection

    Unpacking and Inspection Section 2: Unpacking and Inspection General NOTE: After unpacking, carefully inspect the contents for damage. It is advised to unpack and inspect the unit immediately upon delivery to detect any damage that may have occurred in transit. Any claims for shipping damage need to be filed as soon as possible with the freight carrier.
  • Page 12 Unpacking and Inspection NOTE: The enclosed keys provided with this unit are intended for service personnel use only. 7. There are two locks securing the lid, one on each side (A in Figure 2-4). To properly open the lid, press down, on the lid, above the side lock and unlock the latch.
  • Page 13 Unpacking and Inspection 10. Perform a visual inspection for any hidden freight Figure 2-6 illustrates the following: damage. If damage is present, contact the freight carrier. Customer connection area (underneath and behind the control panel) Fuel regulator Battery compartment Positive (+) and Negative (–) Battery Cables Location of “Parts Shipped Loose”...

  • Page 14: Parts Shipped Loose

    Unpacking and Inspection Parts Shipped Loose Figure 2-8. Parts shipped loose are located in a Main Line Circuit Breaker (MLCB) Locking clear plastic bag inside the battery compartment. The Mechanism flexible fuel line (6) is tied to either the battery wires or the alternator can.

  • Page 15: Section 3: Site Selection And Preparation

    Site Selection and Preparation Section 3: Site Selection and Preparation Site Selection No operable windows or openings in the wall permitted Existing Wall within 1.52 m (5 ft) from any point of the generator. 18 in (457 mm) 5 ft 5 ft Minimum Distance (1.52 m)

  • Page 16: Installation Guidelines For Stationary Air-Cooled Generators

    Site Selection and Preparation the top should be a minimum of 5 ft (1.52 m) from demonstrated that a fire within the enclosure will any structure, overhang or projections from the wall. not ignite combustible materials outside the enclosure. • DO NOT install under wooden decks or structures unless there is at least 5 ft (1.52 m) of clearance Annex A —...

  • Page 17: Site Preparation

    Site Selection and Preparation Material Sufficient for Level Installation For adequate maintenance and airflow clearance, the area above the generator should be at least 5 ft (1.52 m) • Figure 3-3. Dig a rectangular area with a minimum of 3 ft (0.91 m) at the front and ends of approximately 5 in (127 mm) deep [A] and about 6 in the enclosure.
  • Page 18 Site Selection and Preparation This page intentionally left blank. Installation Guidelines for 60 Hz EcoGen™ Generator...

  • Page 19: Section 4: Generator Placement

    Generator Placement Section 4: Generator Placement Generator Placement Fascia Installation (If Applicable) • Locate the four (4) threaded black rubber bumpers Figure 4-1. All air–cooled generators come with a located in the Owner’s Manual bag. composite pad. The composite pad elevates the generator and helps prevent water from pooling around •...
  • Page 20 Generator Placement This page intentionally left blank. Installation Guidelines for 60 Hz EcoGen™ Generator...

  • Page 21: Section 5: Fuel Conversion/Gas Connections

    Fuel Conversion/Gas Connections Section 5: Fuel Conversion/Gas Connections Fuel Requirements and NOTE: All pipe sizing, construction and layout must comply with NFPA 54 for natural gas applications and Recommendations NFPA 58 for liquid propane applications. Once the generator is installed, verify fuel pressure NEVER drops below the required specification.

  • Page 22: Fuel Consumption

    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 ft /h [m...

  • Page 23: Lp Vapor Pipe Sizing

    Fuel Conversion/Gas Connections LP Vapor Pipe Sizing To determine correct LP Vapor pipe size, find the kW NOTE: Pipe sizes are using a second stage regulator. rating of the generator in the left column, and trace to the NOTE: The minimum LP tank size is 250 gallons (946 L), right.

  • Page 24: Flexible Fuel Line

    Fuel Conversion/Gas Connections Checking Gas Line Connections Flexible Fuel Line See B in Figure 5-3 and Figure 5-4. When connecting 1. Check for leaks by spraying all connection points the gas line to the generator, use a hose assembly that with a non–corrosive gas leak detection fluid.

  • Page 25: Natural Gas Vapor Installation (Typical)

    Fuel Conversion/Gas Connections Natural Gas Vapor Installation (typical) 000618a NG BTU = ft /h X 1000 Megajoules = m /h X 37.26 BTU and Pressure Decal Check Distance with Gas Provider Accessory Valve with Manometer Port Size Gas Meter for Generator Load Plus All Appliance Loads Flexible Fuel Line Sediment Trap For Underground Installations, Verify Piping System for Code Compliance...

  • Page 26: Lp Vapor Installation (Typical)

    Fuel Conversion/Gas Connections LP Vapor Installation (typical) 000619b NG BTU = ft /h X 2500 Megajoules = m /h X 93.15 BTU and Pressure Decal Check Distance with Gas Provider Primary Fuel Pressure Regulator Per LP Provider Manual Shutoff Valve Secondary Fuel Pressure Regulator Flexible Fuel Line Sediment Trap...

  • Page 27: Section 6: Electrical Connections

    Electrical Connections Section 6: Electrical Connections Generator Connections NOTE: This wiring can be run in the same conduit if the appropriate insulation rated wire is used. NOTE: Wiring must be performed in accordance with Seal the conduit at the generator in compliance local jurisdiction and codes.

  • Page 28: Control Wiring Notes

    Electrical Connections Main AC Wiring Control Wiring Notes • To separate low voltage from high voltage wires, NOTE: Main AC wiring must be in accordance with local unless NEC Section 300.3(c)(1) requirements are jurisdiction and codes. met, run 2–wire start, N1, N2, and T1 wires through Strip the insulation off the wire ends.

  • Page 29: Automatic Voltage Regulator (Avr) Cooling Fans

    Electrical Connections Automatic Voltage Regulator WARNING (AVR) Cooling Fans Explosion. Batteries emit explosive gases. The system is equipped with two fans to cool the AVR Always connect positive battery cable first to electronics. The primary fan is powered by AC during avoid spark.
  • Page 30 Electrical Connections 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 http://batterycouncil.org.

  • Page 31: Section 7: Control Panel/Start-Up/Testing

    Control Panel/Start–Up/Testing Section 7: Control Panel/Start–Up/Testing Preparing for Start-Up Using the AUTO/MANUAL/OFF Buttons DANGER Button Description of Operation Automatic start-up. Disconnect normal power source Auto Press to activate fully automatic operation. Green and render unit inoperable before working on unit. LED illuminates to confirm that system is in AUTO Failure to do so will result in death or serious injury.

  • Page 32: Before Initial Start-Up

    Control Panel/Start–Up/Testing Before Initial Start–Up SAE 30 NOTE: These units have been run and tested at the factory prior to being shipped and do not require any type 10W-30 of break–in. Synthetic 5W-30 CAUTION Engine damage. Verify proper type and quantity of engine oil prior to starting engine.
  • Page 33 Control Panel/Start–Up/Testing This page intentionally left blank. Installation Guidelines for 60 Hz EcoGen™ Generator...

  • Page 34: Menu Navigation

    Control Panel/Start–Up/Testing Menu Navigation Feature Description System Menus HOME Screen 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 35: Cold Smart Start

    Control Panel/Start–Up/Testing NOTE: If the unit has already been powered up, it will be NOTE: All appropriate panels must be in place during necessary to disconnect the generator battery, fuse and any operation of the generator. This includes operation battery charge circuit (T1 60 Hz / T1 & T2 50Hz). servicing technician while...
  • Page 36 Control Panel/Start–Up/Testing 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...
  • Page 37 Control Panel/Start–Up/Testing 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 38: Electrical Checks

    Control Panel/Start–Up/Testing Electrical Checks The secondary 12 VDC fan continues to operate for up to one hour after the generator is shut down (even if the 7.5 amp ATO fuse is removed). To avoid hand injury, always DANGER exercise caution when working near the AVR fan Electrocution.

  • Page 39: Installation Summary

    Control Panel/Start–Up/Testing Installation Summary 1. Verify the installation has been properly performed as outlined by the manufacturer and that it meets all applicable laws and codes. 2. Test and confirm proper operation of the system as outlined in the appropriate installation and owner’s manuals.
  • Page 40 Control Panel/Start–Up/Testing This page intentionally left blank. Installation Guidelines for 60 Hz EcoGen™ Generator...

  • Page 41: Section 8: Troubleshooting

    Troubleshooting Section 8: Troubleshooting Engine Troubleshooting Table 8-1. 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 cables. 2) Tighten, clean or replace as necessary.* 3) Defective starter contact.

  • Page 42: Generator Troubleshooting

    Troubleshooting Generator Troubleshooting Table 8-2. Generator Troubleshooting Things to Active Alarm Problem Solution Check NONE GREEN Unit running in Check Contact Independent Authorized Servicing Dealer if AUTO but no Generator Generator Disconnect circuit breaker is in the ON position. power in house. Disconnect circuit breaker.

  • Page 43: G-Flex™ Troubleshooting

    Troubleshooting Table 8-2. Generator Troubleshooting (Continued) Things to Active Alarm Problem Solution Check STEPPER Unit will not start Check the Contact Independent Authorized Servicing Dealer. OVERCURRENT in AUTO with 2- LEDs/Screen for wire start signal. alarms. MISWIRE Unit will not start Check the Contact Independent Authorized Servicing Dealer.
  • Page 44 Troubleshooting Table 8-3. G-Flex™ Troubleshooting (Continued) Ecode/Active Things to Problem Possible Causes/Solution Alarm Check 1055 VSCF Phase Unit shuts down Check the An incorrect voltage and frequency has been detected during Error during starting. LEDs/Screen starting. Probable causes are: for alarms. 1) Alternator damage.
  • Page 45 Troubleshooting Table 8-3. G-Flex™ Troubleshooting (Continued) Ecode/Active Things to Problem Possible Causes/Solution Alarm Check 1065 Unit shuts down Check the Probable causes are: Overfrequency during operation. LEDs/Screen 1) Overload. Remove load and attempt to restart unit. for alarms. 2) RPM sensor has failed. Contact Independent Authorized Servicing Dealer.
  • Page 46 Troubleshooting This page intentionally left blank. Installation Guidelines for 60 Hz EcoGen™ Generator...

  • Page 47: Section 9: Accessories

    Accessories Section 9: 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). Scheduled Maintenance Kit Includes all pieces necessary to perform maintenance on the generator along with oil recommendations.
  • Page 48 Accessories This page intentionally left blank. Installation Guidelines for 60 Hz EcoGen™ Generator...

  • Page 49: Section 10: Diagrams

    Diagrams Section 10: Diagrams Installation Drawing (1 of 2) 30.2 [ 30.2 [ 1.2] 1.2] LIFTING HOLES 4 CORNERS LIFTING HOLES 4 CORNERS "DO NOT LIFT BY ROOF" "DO NOT LIFT BY ROOF" 637.6 637.6 1229.5 1229.5 [25.1] [25.1] [48.4] [48.4] 732.5 732.5...

  • Page 50: Installation Drawing (2 Of 2)

    Diagrams Installation Drawing (2 of 2) AIR INTAKE AIR INTAKE 457.2 457.2 [18.0] [18.0] 914 [36.0] 914 [36.0] MINIMUM OPEN AREA MINIMUM OPEN AREA ON SIDES AND FRONT ON SIDES AND FRONT AIR OUTLET AIR OUTLET AIR INTAKE AIR INTAKE HOLE LOCATIONS FOR HOLE LOCATIONS FOR TOP VIEW...

  • Page 51: Off Grid Mode Application Schematic

    Diagrams Off Grid Mode Application Schematic Installation Guidelines for 60 Hz EcoGen™ Generator...

  • Page 52: Oil Make Up System Schematic

    Diagrams Oil Make Up System Schematic Installation Guidelines for 60 Hz EcoGen™ Generator...
  • Page 53 Diagrams This page intentionally left blank. Installation Guidelines for 60 Hz EcoGen™ Generator...
  • Page 54 Diagrams This page intentionally left blank. Installation Guidelines for 60 Hz EcoGen™ Generator...
  • Page 56 Part No. 0K6047 Rev E 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)
  • Page 57 WINDCHILL VERSION AIR INTAKE 457.2 [18.0] 914 [36.0] MINIMUM OPEN AREA ON SIDES AND FRONT AIR OUTLET AIR INTAKE HOLE LOCATIONS FOR TOP VIEW OPTIONAL MOUNTING TO A CONCRETE PAD 1154.0 36.0 10.0 [3/8] DIA. CLEARANCE [45.4] [1.4] HOLE (2) PLACES, 353.7 3/8 DIA.

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