Generac Power Systems EcoGen G0070340 Installation Manuallines
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Generac Power Systems EcoGen G0070340 Installation Manuallines

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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)
WARNING
(000209a)

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Summary of Contents for Generac Power Systems EcoGen G0070340

  • Page 1 Installation Guidelines 60 Hz Air-Cooled Generators 15 kW EcoGen™ 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 1-888-GENERAC (888-436-3722)
  • 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 owner’s Model: manual. The unit has a label plate affixed to the inside parti- tion, to the left of the control panel console.

  • Page 3: Table Of Contents

    Table of Contents Section 1: Safety Rules & General Fuel Requirements and Recommendations ... 17 Information Fuel Conversion ..........17 Introduction ............1 Fuel Consumption ..........18 Read This Manual Thoroughly ........1 Fuel Line Sizing ..........18 How to Obtain Service ..........1 Natural Gas Pipe Sizing ..........19 Safety Rules ............2 LP Vapor Pipe Sizing ..........19...
  • Page 4 Table of Contents Installation Summary ........37 Shutting Generator Down While Under Load or During An Extended Outage ......37 To turn 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...

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

    Safety Rules & General Information Section 1: Safety Rules & General Information Introduction SAVE THESE INSTRUCTIONS: The manufacturer suggests that this manual and the rules for safe operation Thank purchasing this compact, high- be copied and posted near the unit installation site. performance, variable speed, air-cooled, engine-driven Safety should be stressed to all operators and potential stationary automatic standby generator set.

  • Page 6: Safety Rules

    Safety Rules & General Information When contacting an IASD about parts and service, WARNING always supply the complete model number and serial number of the unit as given on its data decal, which is Accidental Start-up. Disconnect the negative battery located on the generator.

  • Page 7: Exhaust Hazards

    Safety Rules & General Information Electrical Hazards WARNING DANGER Risk of injury. Do not operate or service this machine if not fully alert. Fatigue can impair the ability to service Electrocution. Contact with bare wires, this equipment and could result in death or serious terminals, and connections while generator injury.

  • Page 8: Fire Hazards

    Safety Rules & General Information Fire Hazards Explosion Hazards DANGER WARNING Explosion and fire.Fuel and vapors are extremely Fire hazard. Do not obstruct cooling and flammable and explosive. No leakage of fuel is ventilating airflow around the generator. Inadequate permitted. Keep fire and spark away. Failure to do ventilation could result in fire hazard, possible so will result in death or serious injury.

  • Page 9: General Rules

    Safety Rules & General Information General Rules • Fully comply with all relevant NEC, NFPA, and OSHA standards, as well as all federal, state, and local building and electric codes. As with any DANGER generator, this unit must be installed in accordance Loss of life.
  • Page 10 Safety Rules & General Information 13. International Building Code ** 14. Agricultural Wiring Handbook *** 15. Article X, NATIONAL BUILDING CODE 16. ASAE EP-364.2 Installation and Maintenance of Farm Standby Electric Power **** 17. 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.

  • Page 11: Section 2: Unpacking And Inspection

    Unpacking and Inspection Section 2: Unpacking and Inspection General NOTE: Carefully inspect the contents for damage after unpacking. 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. 3. Two locks secure the lid; one on each side (A in Figure 2-4). Press down on the lid above the side lock and unlock the latch to properly open the lid.

  • Page 13: Intake Side Panel Removal

    Unpacking and Inspection Intake Side Panel Removal 3. Lift the intake panel up and away from the generator. Figure 2-5. The intake side panel (A) must be NOTE: Always lift the intake side panel straight up removed to access the battery compartment, fuel before pulling away from enclosure.

  • Page 14: Generator Main Line Circuit Breaker

    Unpacking and Inspection Generator Main Line Circuit Parts Shipped Loose Breaker This is a 2-pole circuit breaker (generator disconnect) rated according to relevant specifications. See “A” in Figure 2-8. 003599 Keys Flexible fuel line Battery terminal cap Figure 2-8. Generator Main Line Circuit Breaker Rubber mounts (only for units that include fascia) Fascia (if applicable) The breaker can be locked in the OFF (OPEN) position...

  • Page 15: Section 3: Site Selection And Preparation

    Site Selection and Preparation Section 3: Site Selection and Preparation Site Selection 5 ft (1.52 m) 5 ft (1.52 m) 3 ft 3 ft (0.91 m) (0.91 m) 3 ft (0.91 m) 001751 001789 Figure 3-1. Installation Clearances Description Comments Top of generator —...

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

    Site Selection and Preparation Install the generator set, in its protective enclosure, – The generator must be installed on a level sur- outdoors where adequate cooling and ventilating air is face. The generator must be level within a 0.5 in always available (Figure 3-1).

  • Page 17: Site Preparation

    Site Selection and Preparation Site Preparation generator enclosure would not pose any ignition risk to nearby combustibles or structures, with or without fire • Locate the mounting area as close as possible to service personnel response. the connected loads and fuel supply. •...

  • Page 18: Transportation Recommendations

    Site Selection and Preparation Transportation Recommendations Use a suitable cart or equipment to carry the generator, including the wooden pallet, to the installation site. Place cardboard between the hand cart and the generator to prevent any damage or scratches to the generator. IMPORTANT NOTE: Do not lift, carry, or move the generator by grasping the louvers.

  • Page 19: Section 4: Generator Placement

    Generator Placement Section 4: Generator Placement Generator Placement All air-cooled generators come with a non-sinking direct to dirt (DTD) composite base pad. The DTD pad elevates the generator and helps prevent water from pooling around the base. (Figure 4-1). The DTD pad allows the generator to be placed on three types of surfaces: •...

  • Page 20: Fascia Installation (If Applicable)

    Generator Placement Fascia Installation (If Applicable) • Locate the four threaded black rubber bumpers supplied with the loose parts. • Remove the four rubber mounts from the bag and screw them into threaded holes located inside the end pieces of the fascia (two each) opposite one another (A).

  • 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 or ICC IFGC for liquid propane applications. Verify fuel pressure NEVER drops below the required DANGER specification once the generator is installed.

  • Page 22: Fuel Consumption

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

  • Page 23: Natural Gas Pipe Sizing

    Fuel Conversion / Gas Connections Natural Gas Pipe Sizing To determine correct gas pipe size, find the kW rating of NOTE: Add 2.5 ft (0.76 m) per any bend, tee, or angle in the generator in the left column, and trace to the right. the pipe to the overall distance.

  • Page 24: Installing And Connecting Gas Lines

    Fuel Conversion / Gas Connections Installing and Connecting Gas Lines Flexible Fuel Line DANGER When connecting the gas line to the generator, use a Explosion and fire.Fuel and vapors are extremely listed assembly that meets the requirements of ANSI flammable and explosive. No leakage of fuel is Z21.75/ CSA 6.27—Connectors for Outdoor Gas permitted.

  • Page 25: Checking Gas Line Connections

    Fuel Conversion / Gas Connections Checking Gas Line Connections Perform Leak Test 1. Check for leaks by spraying all connection points DANGER with a non-corrosive gas leak detection fluid. The solution should not be blown away or form bubbles. Explosion and fire.Fuel and vapors are extremely 2.

  • Page 26: Natural Gas Vapor Installation (Typical)

    Fuel Conversion / Gas Connections Natural Gas Vapor Installation (typical) NG BTU = ft /h X 1000 Megajoules = m /h X 37.26 BTU and pressure decal Minimum distance from rear obstruction—see Site Selection Manual shutoff valve (pressure port optional) Pipe nipple (field supplied) Flexible fuel line Check distance with gas provider...

  • Page 27: Lp Vapor Installation (Typical)

    Fuel Conversion / Gas Connections LP Vapor Installation (typical) 001809 LP BTU = ft LP BTU = ft /h X 2500 /h X 2500 Megajoules = m Megajoules = m /h X 93.15 /h X 93.15 BTU and pressure decal BTU and pressure decal Minimum distance from rear obstruction—see Minimum distance from rear obstruction...
  • Page 28 Fuel Conversion / Gas Connections This page intentionally left blank. Installation Guidelines For 60 Hz EcoGen™ Generators...

  • Page 29: 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 the intake side panel as directed in Intake Side Panel Removal, and then remove the access panel. Connect wires according to the diagram and tables.

  • Page 30: Control Wiring

    Electrical Connections Control Wiring Figure 6-1. l Electrical Wiring Connections Table 6-1. Electrical Wiring Connection Points Description Description Description Description Control wire terminal block Wire tie for sense wires Power lug E2 Neutral stud Sense wire terminal block Neutral lug Ground stud Neutral bar Wire tie for control wires...

  • Page 31: Main Ac Wiring

    Electrical Connections Main AC Wiring NOTE: Main AC wiring must be in accordance with local jurisdiction and codes. NOTE: The generator lugs are rated at 167 °F (75 °C), copper or aluminum. 1. Strip the insulation off the wire ends. Do not remove excessive insulation.

  • Page 32: Common Alarm Relay (Option)

    Electrical Connections Common Alarm Relay (Option) WARNING Alarms relating to generator and engine performance appear on the controller and in the Mobile Link™ application (if used). The controller is equipped with a common alarm relay that provides contacts for an (000138a) optional customer-supplied external alarm indicator.

  • Page 33: Battery Disposal

    Electrical Connections NOTE: In areas where temperatures fall below 0°F (-18°C), it is recommended that a pad type battery warmer be installed to aid in cold climate starting. This is available through an Independent Authorized Service Dealer (IASD). A battery warmer is not necessary for AGM-style batteries. Battery Disposal WARNING Environmental Hazard.
  • Page 34 Electrical Connections This page intentionally left blank Installation Guidelines For 60 Hz EcoGen™ Generators...

  • Page 35: Section 7: Control Panel Start-Up/Testing

    Control Panel Start-Up/Testing Section 7: Control Panel Start-Up/Testing Control Panel Interface Generator Setup The controller will light up when battery power is applied DANGER to the generator during the installation process. The generator still needs to be activated before it will Automatic start-up.
  • Page 36 Control Panel Start-Up/Testing NOTE: The USB port is intended for use with a USB LED lights. Do not connect any consumer electronics to flash drive only. The USB port is not intended for the USB port charging or powering any devices such as phones or Table 7-1.
  • Page 37 Control Panel Start-Up/Testing Table 7-1. Activation Chart Display Reads Troubleshooting Use arrow keys to Serial 123456789 scroll and find the first Passcode XXXXX +/- number your Activation Code. Press ENTER select. Repeat this step until all digits have been entered. ESCAPE correct previous digits.

  • Page 38: Before Initial Start-Up

    Control Panel Start-Up/Testing Before Initial Start-up shutoff valves in the fuel supply lines must be open. NOTE: The unit has been run and tested at the factory NOTE: During initial start up only, the generator may prior to being shipped and does not require any type of exceed the normal number of start attempts and break-in.
  • Page 39 Control Panel Start-Up/Testing necessary. If unit fails to start, contact an Independent Authorized Service Dealer (IASD) for assistance. Power Up Unit Note: If language was previously programmed this goes directly FIRMWARE V 1.01 to “Select Hour” HARDWARE V 1.05 UP ARROW = Language Install Wizard + English -...

  • Page 40: 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 housing.

  • Page 41: Checking Automatic Operation

    Control Panel Start-Up/Testing Checking Automatic Operation 1. Press AUTO on the control pad. The system is now ready for automatic operation. 2. Verify that the remote two–wire start test switch installed near the Alternative Power Management System is set to the ON (Closed) position. This will cause the generator to start automatically.
  • Page 42 Control Panel Start-Up/Testing This page intentionally left blank. Installation Guidelines For 60 Hz EcoGen™ Generators...

  • Page 43: 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 44: Generator Troubleshooting And System Diagnosis

    Troubleshooting Generator Troubleshooting and System Diagnosis To clear an active alarm, press the OFF button, ENTER button, then press AUTO. Contact an Independent Authorized Service Dealer (IASD) if the alarm reoccurs. Table 8-2. Generator Troubleshooting Things to Active Alarm Problem Solution Check Check the...
  • Page 45 Troubleshooting Table 8-2. Generator Troubleshooting (Continued) Things to Active Alarm Problem Solution Check Check Unit running in FLASHING Generator If the Generator Disconnect circuit breaker is in the ON NONE AUTO but no Disconnect position, contact an IASD. GREEN power in house. circuit breaker.

  • Page 46: Avr Troubleshooting

    Troubleshooting Table 8-2. Generator Troubleshooting (Continued) Things to Active Alarm Problem Solution Check Unit will not start in AUTO with Check the UNDER remote two-wire LEDs/Screen for Contact Independent Authorized Servicing Dealer. VOLTAGE start set to the ON alarms. (CLOSED) position.
  • Page 47 Troubleshooting Table 8-3. AVR 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 48 Troubleshooting Table 8-3. AVR 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 49: Section 9: Accessories

    Accessories Section 9: 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 50 Accessories This page intentionally left blank. Installation Guidelines For 60 Hz EcoGen™ Generators...

  • Page 51: Section 10: Diagrams

    Diagrams Section 10: Diagrams IInstallation Drawing (10000002491—1 of 2) AIR INTAKE 457.2 [18.0] 914 [36.0] MINIMUM OPEN AREA ON SIDES AND FRONT AIR INTAKE AIR OUTLET TOP VIEW "DO NOT LIFT BY ROOF" RIGHT VIEW INTAKE PANEL REMOVED 30.2 [ 1.2] LIFTING HOLES 4 CORNERS 1218.0 [48.0]...

  • Page 52: Installation Drawing (10000002487-2 Of 2)

    Diagrams Installation Drawing (10000002487—2 of 2) MOUNTING TO CONCRETE PAD 1154.0 [45.4] 340.7 [13.4] HOLE LOCATIONS FOR OPTIONAL MOUNTING TO A CONCRETE PAD 536.8 10.0 [3/8] DIA. CLEARANCE [21.1] HOLE (4) PLACES, 3/8 DIA. MASONRY ANCHOR BOLTS RECOMMENDED 68.0 456.6 392.7 [2.7] [18.0]...

  • Page 53: Off Grid Mode Application Schematic

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

  • Page 54: Oil Make Up System Schematic

    Diagrams Oil Make Up System Schematic Installation Guidelines For 60 Hz EcoGen™ Generators...
  • Page 56 ©2017 Generac Power Systems, Inc. S45 W29290 Hwy. 59 All rights reserved Waukesha, WI 53189 Specifications are subject to change without notice. 1-888-GENERAC (1-888-436-3722) No reproduction allowed in any form without prior written www.generac.com consent from Generac Power Systems, Inc.

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