Generac Power Systems EcoGen 15kW Installation Manuallines
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Generac Power Systems EcoGen 15kW Installation Manuallines

60 hz air-cooled generators
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Installation Guidelines
60 Hz Air-Cooled Generators
15kW EcoGen™
Loss of life. 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
WARNING
(000209b)
(888-436-3722)
®

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  • Page 1 ® Installation Guidelines 60 Hz Air-Cooled Generators 15kW EcoGen™ WARNING Loss of life. 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. (000209b) Register your Generac product at: WWW.GENERAC.COM...
  • Page 2 Use this page to record important information about this generator. Record the information found on the unit data label on this page. For the location of the unit data label, see owner’s Model: 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 Water Ingress Avoidance ..........16 Information Proximity to Utilities ..........16 Verify Wi-Fi Range ............16 Introduction ..............1 Read This Manual Thoroughly ........1 Transportation Recommendations ......17 Safety Rules ..............1 Suitable Mounting Surface ........17 How to Obtain Service ..........2 Placement on Roofs, Platforms, and Other General Hazards ............2 Supporting Structures ..........17...
  • Page 4 Table of Contents Section 7: Control Panel Startup/Testing Control Panel Interface ..........35 Using the AUTO/MANUAL/OFF Buttons ....35 Generator Setup ............35 Activation ..............35 Cold Smart Start ............37 Setting The Exercise Timer ........37 Before Initial Startup ..........37 Install Wizard ............

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

    Safety Rules & General Information Section 1: Safety Rules & General Information Introduction SAVE THESE INSTRUCTIONS for future reference. This manual contains important instructions that must be fol- Thank you for purchasing this compact, high perfor- lowed during placement, operation, and maintenance of mance, air-cooled, engine-driven generator.

  • Page 6: How To Obtain Service

    Safety Rules & General Information How to Obtain Service WARNING When the unit requires servicing or repairs, contact Gen- erac Customer Service at 1-888-GENERAC (1-888-436- Equipment damage. This unit is not intended for use as a prime 3722) or visit www.generac.com for assistance.

  • Page 7: Exhaust Hazards

    Safety Rules & General Information DANGER WARNING Injury and equipment damage. Do not use generator Electrical backfeed. Use only approved switchgear to as a step. Doing so could result in falling, damaged isolate generator from the normal power source. Failure to do so will result in death, serious injury, parts, unsafe equipment operation, and could result and equipment damage.

  • Page 8: Explosion Hazards

    Safety Rules & General Information DANGER WARNING Fire and explosion. Installation must comply with all Risk of fire. Allow fuel spills to completely dry local, state, and national electrical building codes. before starting engine. Failure to do so will Noncompliance could result in unsafe operation, result in death or serious injury.

  • Page 9: General Rules

    Safety Rules & General Information WARNING WARNING Risk of burn. Do not open or mutilate batteries. Consult Manual. Read and understand manual Batteries contain electrolyte solution which can cause completely before using product. Failure to burns and blindness. If electrolyte contacts skin or completely understand manual and product eyes, flush with water and seek immediate medical could result in death or serious injury.

  • Page 10: Standards Index

    Safety Rules & General Information Standards Index www.nfpa.org www.iccsafe.org WARNING www.rerc.org Rural Electricity Resource Council P.O. Box 309 Wilmington, OH 45177-0309 Loss of life. This product is not intended to **** www.asabe.org American Society of Agricultural & be used in a critical life support application. Biological Engineers 2950 Niles Road, St.

  • Page 11: Section 2: Unpacking And Inspection

    Unpacking and Inspection Section 2: Unpacking and Inspection General Unpacking 1. Remove outer shipping carton. NOTE: Carefully inspect contents for damage after unpacking. Unpack and inspect unit immediately upon 2. See Figure 2-1. Remove wood frame. delivery to identify any damage which may have occurred in transit.

  • Page 12: Opening The Lid

    Unpacking and Inspection Enclosure Panel Removal IMPORTANT NOTE: DO NOT perform next step until generator has been transported to installation site. Generator installation requires removal of front panel and 4. See Figure 2-3. Remove bolts and pallet brackets intake side panel. Remove these panels when neces- (A).

  • Page 13: Intake Side Panel Removal

    Unpacking and Inspection Customer Connections and Loose Intake Side Panel Removal Parts Figure 2-6. The intake side panel (A) must be removed to access battery compartment, fuel regulator, Figure 2-7 Figure 2-8 for customer connections and sediment trap. and loose parts location. Figure 2-10 illustrates parts 1.

  • Page 14: Generator Main Line Circuit Breaker

    Unpacking and Inspection Generator Main Line Circuit Breaker Parts Shipped Loose Figure 2-9. The 2-pole main line circuit breaker (MLCB) (generator disconnect) (A) is rated according to relevant specifications. 003599a Keys Flexible fuel line 001810 Figure 2-9. Generator Main Line Circuit Breaker Battery terminal cap (MLCB) Rubber mounts...

  • Page 15: Auxiliary Shutdown Switch

    Unpacking and Inspection Auxiliary Shutdown Switch CAUTION Equipment Damage. The auxiliary shutdown switch is not to be used to power down the unit under normal operating circumstances. Doing so will result in equipment damage. (000399) All generators are equipped with an external means of shutting down the generator which complies with the lat- est NEC code requirement.
  • Page 16 Unpacking and Inspection This page intentionally left blank. Installation Guidelines For 60 Hz EcoGen™ Generators...

  • Page 17: Section 3: Site Selection And Preparation

    Site Selection and Preparation Section 3: Site Selection and Preparation Site Selection Carbon Monoxide Site selection is critical for safe generator operation. It is important to discuss these factors with the installer when DANGER selecting a site for generator installation: Asphyxiation.

  • Page 18: Potential Co Entry Points

    Site Selection and Preparation Potential CO Entry Points Protect the Structure Verify structure itself is correctly caulked and sealed to Figure 3-1. Generator exhaust can enter a structure prevent air from leaking in or out. Voids, cracks, or open- through large openings, such as windows and doors. ings around windows, doors, soffits, pipes, and vents can However, exhaust and CO can also seep into the struc- allow exhaust gas to be drawn into the structure.

  • Page 19: Distance Requirements

    Site Selection and Preparation Fire Prevention The generator must be installed at a safe distance away Distance Requirements from combustible materials. Engine, alternator, and Figure 3-2. Minimum clearances must be main- exhaust system components become very hot during tained around the generator enclosure. These clear- operation.

  • Page 20: Fire Codes, Standards, And Guidelines

    Site Selection and Preparation Fire Codes, Standards, and Guidelines Generator Maintenance Generator installation must comply strictly with ICC Regular maintenance is crucial for minimizing exhaust IFGC, NFPA 37, NFPA 54, NFPA 58, and NFPA 70 stan- emissions and reducing the risk of fire or equipment fail- dards.

  • Page 21: Transportation Recommendations

    Site Selection and Preparation Transportation Recommendations Placement on Roofs, Platforms, and Other Supporting Structures Use a suitable cart or equipment to carry generator, including wooden pallet, to installation site. Place card- Where required to place generator on a roof, platform, board between cart and generator to prevent any dam- deck, or other supporting structure, generator must be age or scratches to generator.
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  • Page 23: Section 4: Generator Placement

    Generator Placement Section 4: Generator Placement Generator Placement Three 3/8 in (or M10) lag bolts (not supplied) are recom- mended for securing the generator to a concrete pad. Figure 4-1. All air-cooled generators come with a NOTE: The top of the generator carton has a template composite pad.

  • Page 24: Base Plug Installation (If Applicable)

    Generator Placement Base Plug Installation (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. 3.

  • Page 25: Section 5: Fuel Conversion / Gas Connections

    Fuel Conversion / Gas Connections Section 5: Fuel Conversion / Gas Connections Fuel Requirements and Piping strength and connections should be given special consideration for installations in areas at risk for flooding, Recommendations tornadoes, hurricanes, earthquakes, unstable ground. DANGER IMPORTANT NOTE: Use an approved pipe sealant Explosion and fire.

  • Page 26: Fuel Consumption

    Fuel Conversion / Gas Connections Fuel Consumption Natural Gas Propane Generator 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 m /h / ft ** Propane is in gal/h (LP) / L/h (LP) / ft /h (LPV)

  • Page 27: Natural Gas Pipe Sizing

    Fuel Conversion / Gas Connections Natural Gas Pipe Sizing To determine correct NG pipe size, find the kW rating of NOTE: See Table B.3.2 in NFPA 54 or Table A.2.2 in the generator in the left column, and trace to the right. The ICC IFGC, Equivalent Lengths of Pipe Fittings and number to the right is maximum length (measured in ft / Valves for the correct values to be added to overall fuel...

  • Page 28: Installing And Connecting Fuel Lines

    Fuel Conversion / Gas Connections Installing and Connecting Fuel Lines DANGER Explosion and fire. Fuel and vapors are 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. (000192) IMPORTANT NOTE: NG and LP gas are highly vola- tile substances.

  • Page 29: Checking Fuel Line Connections

    Fuel Conversion / Gas Connections Checking Fuel Line Connections Performing Fuel System Leak Test Checking Fuel Pressure DANGER Proceed as follows to check fuel pressure at the regulator Explosion and fire. Fuel and vapors are extremely in the generator: flammable and explosive. No leakage of fuel is 1.
  • Page 30 Fuel Conversion / Gas Connections Natural Gas Installation (Typical) 008965 NG BTU/h = ft /h X 1000 Megajoules/h = m /h X 37.26 Fuel data decal Minimum distance from rear obstruction—see Distance Requirements Manual fuel shutoff valve (pressure port optional) Must be located no more than 6 ft (1.83 m) away from fuel inlet Pipe fittings (field supplied) Flexible fuel line...
  • Page 31 Fuel Conversion / Gas Connections LP Gas (Vapor) Installation (Typical) 008966 LPG BTU/h = ft /h X 2500 Megajoules/h = m /h X 93.15 Fuel data decal Minimum distance from rear obstruction—see Distance Requirements Manual fuel shutoff valve (pressure port optional) Must be located no more than 6 ft (1.83 m) away from fuel inlet.
  • Page 32 Fuel Conversion / Gas Connections This page intentionally left blank. Installation Guidelines For 60 Hz EcoGen™ Generators...

  • Page 33: Section 6: Electrical Connections

    Electrical Connections Section 6: Electrical Connections Generator Connections Figure 6-1. The electrical wiring enclosure is located behind an access panel on the intake end of the unit. Remove intake side panel as directed in Intake Side Panel Removal, and then remove access panel. Con- nect wires according to diagram and tables.

  • Page 34: Control Wiring

    Electrical Connections Control Wiring UTILITY SENSE GROUND + 12 VDC VAC LOAD SUPPLY TRANSFER GROUND UTILITY SENSE + 12 VDC VAC LOAD TRANSFER SUPPLY 005810 Figure 6-1. Electrical Wiring Connections Table 6-1. Electrical Wiring Connection Points Description Description Description Description Control wire terminal block Wire tie for control wires Power lug E2...

  • Page 35: Main Ac Wiring

    Electrical Connections Figure 6-1. Connect a suitably sized system bond- Table 6-4. Ground and Neutral Connections ing jumper in accordance with NEC Table 250.102(C)(1) (Copper or Aluminum Conductors) from neutral bar (J) to ground stud (F). Tighten ground stud nut to 35 in-lbs (3.95 Nm). This is required when See national and/or local codes to verify correct wire sizes.

  • Page 36: Battery Requirements

    Electrical Connections Battery Requirements Complete the following steps before installing and con- necting battery: 12 volts, Group 26R Wet Cell 540CCA minimum, or 1. Verify generator is OFF. Group 35 AGM 650CCA minimum. 2. Turn off utility power supply to transfer switch. If internal battery charger is not connected to utility 3.

  • Page 37: Battery Disposal

    Electrical Connections NOTE: Battery heater and oil heater require N1 and N2 connections to 240V utility. Breather heater requires T1 connection to 120V. NOTE: A battery warmer is not necessary for AGM-style batteries. Battery Disposal WARNING Environmental Hazard. Always recycle batteries at an official recycling center in accordance with all local laws and regulations.
  • Page 38 Electrical Connections This page intentionally left blank. Installation Guidelines For 60 Hz EcoGen™ Generators...

  • Page 39: Section 7: Control Panel Startup/Testing

    Control Panel Startup/Testing Section 7: Control Panel Startup/Testing Control Panel Interface 1. The display interface will launch Install Wizard upon first power-up of the generator. The control panel interface is located under the enclo- 2. Follow on-screen instructions on the generator sure lid.
  • Page 40 Control Panel Startup/Testing Display Reads Troubleshooting Language English Use arrow keys to scroll to desired lan- Language can be changed later using guage. the EDIT menu. Press ENTER to select. 002227 Enable Wi-Fi? Use arrow keys to either enable or disable Wi-Fi.

  • Page 41: Cold Smart Start

    Control Panel Startup/Testing Display Reads Troubleshooting Select Hour (0-23) - 6 + Activation is complete when this screen is dis- played. Follow controller prompts to complete installation. 002231 Before Initial Startup Cold Smart Start The Cold Smart Start feature is factory-enabled, and can be disabled in the EDIT menu.

  • Page 42: Before Starting, Complete The Following

    Control Panel Startup/Testing Before starting, complete the following: 1. Verify generator is OFF. 2. Set generator MLCB (generator disconnect) to OFF (OPEN). 3. Turn OFF all breakers to be supplied by generator. 4. Verify auxiliary shutdown switch(es) are CLOSED (I). 5.
  • Page 43 Control Panel Startup/Testing Figure 7-3. Install Wizard Menu Map Installation Guidelines For 60 Hz EcoGen™ Generators...
  • Page 44 Control Panel Startup/Testing Figure 7-4. Install Wizard Menu Map Installation Guidelines For 60 Hz EcoGen™ Generators...

  • Page 45: Checking Manual Transfer Switch Operation

    Control Panel Startup/Testing Checking Manual Transfer Switch set generator MLCB (generator disconnect) to ON (CLOSED). Record running fuel pressure: Operation ______________. 10. Connect a calibrated accurate AC voltmeter and a DANGER frequency meter across transfer switch terminal lugs E1 and E2. Voltage should be 238–242V at a Electrocution.

  • Page 46: Generator Tests Under Load

    Control Panel Startup/Testing Generator Tests Under Load 16. Allow engine to run at no-load for 2–5 minutes. 17. Press generator OFF button. Engine will shut down. DANGER Off-Grid Mode ENABLED Electrocution. Do not manually transfer under load. Disconnect transfer switch from all power sources Proceed as follows to test unit with electrical loads prior to manual transfer.

  • Page 47: Checking Automatic Operation

    Control Panel Startup/Testing Checking Automatic Operation Installation Summary 1. Verify installation has been performed correctly as Off-Grid Mode DISABLED outlined by the manufacturer and that it meets all Proceed as follows to check system for correct automatic applicable laws and codes. operation when unit is equipped with a transfer switch 2.
  • Page 48 Control Panel Startup/Testing This page intentionally left blank. Installation Guidelines For 60 Hz EcoGen™ Generators...

  • Page 49: Section 8: Troubleshooting

    Troubleshooting Section 8: Troubleshooting Generator Troubleshooting Problem Cause Correction Correct short circuit condition by replacing 7.5 Blown fuse. A fuse in generator control panel. Contact an IASD if fuse continues to blow. Loose, corroded, or faulty battery cables. Engine will not crank Faulty starter contact.
  • Page 50 Troubleshooting Problem Cause Correction Generator MLCB (generator disconnect) is Set generator MLCB (generator disconnect) to OFF (OPEN). ON (CLOSED). Faulty transfer switch coil. No transfer to Faulty transfer relay. standby after Contact an IASD for assistance. utility source Transfer relay circuit open. failure ** Faulty control logic board.

  • Page 51: Section 9: Quick Reference Guide

    Quick Reference Guide Section 9: Quick Reference Guide System Diagnosis To clear an active alarm, press OFF mode button on control panel, then ENTER button. Then press AUTO mode button. Contact an IASD if alarm reoccurs. Active Alarm Problem Action Solution Check generator FLASHING...
  • Page 52 Quick Reference Guide Active Alarm Problem Action Solution Unit will not start in Check LED’s / Screen OVERVOLTAGE Contact an IASD. AUTO with utility loss. for alarms. AUXILIARY Check auxiliary Set auxiliary shutdown switch(es) to Unit will not start. SHUTDOWN shutdown switch(es).

  • Page 53: Section 10: Accessories

    Accessories Section 10: Accessories Performance enhancing accessories are available for air-cooled generators. Accessory Description Cold Weather Accessories*— • • Battery Pad Warmer Recommended in areas where temperatures fall below 0 °F (-18 °C). (Not necessary for use with AGM-style batteries) •...
  • Page 54 Accessories This page intentionally left blank. Installation Guidelines For 60 Hz EcoGen™ Generators...

  • Page 55: Section 11: Diagrams

    Diagrams Section 11: Diagrams Installation Drawing (10000037315 rev A—1 of 2) MOUNTING TO CONCRETE PAD HOLE LOCATIONS FOR OPTIONAL MOUNTING TO A CONCRETE PAD [20.5] 16 [5/8] DIA. CLEARANCE HOLE (3) PLACES, 10 [3/8] DIA. MASONRY ANCHOR BOLTS RECOMMENDED 19.7 [7.7] [2.7] [18.0]...

  • Page 56: Installation Drawing (10000037315 Rev B-2 Of 2)

    Diagrams Installation Drawing (10000037315 rev B—2 of 2) AIR INTAKE 457 [18.0] MINIMUM OPEN AREA 914 [36.0] MINIMUM OPEN AREA AIR INTAKE AIR OUTLET 914 [36.0] MINIMUM OPEN AREA TOP VIEW 914 [36.0] MINIMUM OPEN AREA "DO NOT LIFT BY ROOF" LIFTING HOLES 4 CORNERS: 30 [ 1.2] - MUST BE LIFTED WITH STEEL RODS...

  • Page 57: Off-Grid Mode Application Schematic

    Diagrams Off-Grid Mode Application Schematic Installation Guidelines For 60 Hz EcoGen™ Generators...

  • Page 58: Oil Make Up System Schematic

    Diagrams Oil Make Up System Schematic Installation Guidelines For 60 Hz EcoGen™ Generators...
  • Page 60 ©2022 Generac Power Systems, Inc. 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. www.generac.com...

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