Installation Guidelines For Automatic Standby Generator 15 kW EcoGen™ * * NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS. * DEADLY EXHAUST FUMES! OUTDOOR INSTALLATION ONLY! ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! This manual should remain with the unit. This manual must be used in conjunction with the appropriate owner’s manual. Para español , visita: http://www.generac.com/service‐support/product‐support‐lookup Pour le français, visiter : http://www.
WARNING California Proposition 65. Engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. (000004) WARNING California Proposition 65. This product contains or emits chemicals known to the state of California to cause cancer, birth defects, and other reproductive harm.
Table of Contents Section 1 1.1 Introduction .......................................................................................................................... 1 1.1.1 Read This Manual Thoroughly ...................................................................................................... 1 1.1.2 How to Obtain Service .................................................................................................................. 2 1.2 Safety Rules ........................................
Table of Contents Section 6 Electrical Connections 6.1 Generator Connections ......................................................................................................27 6.2 Control Wiring .....................................................................................................................27 6.3 Main AC Wiring ...................................................................................................................29 6.4 Automatic Voltage Regulator (AVR) Cooling Fans ..
Section 1 Safety and General Information 1.1 — Introduction Thank you for purchasing this compact, high performance, variable speed, air-cooled, engine-driven stationary automatic standby generator set. Every effort has been made to ensure that the information and instructions in this manual are both accurate and complete at the time of release. However, the manufacturer reserves the right to change, alter, or otherwise improve this product at any time without prior notice.
* $ ! + This symbol points out important safety information that, if not followed, could endanger personnel and/or property. This symbol represents the potential for an Explosion Hazard. This symbol represents the potential for a Fire Hazard. This symbol represents the potential for an Electrical Shock Hazard. The operator is responsible for proper and safe use of the equipment.
1.2.1— General Hazards • For safety reasons, the manufacturer recommends that this equipment be installed by an independent Sales or Service Dealer or other competent, qualified electrician or installation technician who is familiar with applicable codes, standards and regulations. The operator also must comply with all such codes, standards and regulations. Only an Independent Authorized Service Dealer is allowed to perform warranty service on this unit.
ing codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure that the generator is installed in accordance with the manufacturer’s instructions and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes, standards, laws and regulations. • Keep a fire extinguisher near the generator at all times.
5. NFPA 54: National Fuel Gas Code * 6. NFPA 58: Standard for Storage And Handling Of Liquefied Petroleum Gases * 7. NFPA 68: Standard On Explosion Protection By Deflagration Venting * 8. NFPA 70E: Standard For Electrical Safety In The Workplace * 9. NFPA 211: Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances * 10. NFPA 220: Standard on Types of Building Construction * 11. NFPA 5000: Building Code * 12. International Building Code ** 13.
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Section 2 Unpacking and Inspection 2.1 — General NOTE: After unpacking, carefully inspect the contents for damage. Thoroughly inspect the unit immediately upon delivery to determine if any damage occurred in transit. Any claims for shipping damage need to be filed with the freight carrier as soon as possible. This is especially important if the generator is not be installed for a period of time. Any shipping damage, whether obvious or not readily apparent, is not covered by the warranty.
Unpacking and Inspection 2.3 — Unpacking 1. Remove shipping carton. See Figure 2-1. Wooden Frame 15 kW Generator Figure 2-1. Unpack Generator 2. Remove four bolts with crating clamps. Carefully lift the generator off the wooden pallet. Do NOT drag the generator off the pallet or damage to the base will occur. See Figure 2-2. Lid 15 kW Front Access Panel Pallet Crating Clamps (4) Figure 2-2.
Unpacking and Inspection The lid of the generator enclosure is locked. Open the side door compartment and carefully cut the cable strap to release the keys from the circuit breaker switch. See Figure 2-3. 65 3. Figure 2-3. Open Side Door Compartment to Obtain Keys 4. The lid is secured by two locks, one on each side of the enclosure. For best results, press down on the lid directly above the side lock, and while holding the lid down, use key to unlock the latch.
Unpacking and Inspection Connection Area (Under Control Pad) Fuel Regulator Loose Parts Battery Compartment Figure 2-4. Customer Connection Area/Loose Parts Location 9.
Unpacking and Inspection 2.
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Section 3 Site Selection and Preparation 3.1 — Site Selection No operable windows or openings in the wall permitted within 5 ft (1.52 m) from any point of the generator. Existing Wall 60 in (1524 mm) Clearance from operable windows, doors or any openings in the wall. 36 in (914 mm) These guidelines are based upon fire testing of the generator enclosure and the manufacturer’s requirement for air flow for proper operation. Local codes may be different and more restrictive than what is described here.
Site Selection and Preparation Install the generator outdoors in its protective enclosure where adequate cooling and ventilating air is always available. Also consider these other factors: • Installation must strictly comply with NFPA 37, NFPA 54, NFPA 58, and NFPA 70 standards. • Install the generator where air inlet and outlet openings will not be obstructed by leaves, grass, snow, etc. If prevailing winds can cause blowing or drifting, use a windbreak for protection.
Site Selection and Preparation Figure 3-2. Southwest Research Institute Decal Southwest Research Institute Decal (located inside the generator, next to the generator’s data decal) http://www.swri.org/4org/d01/fire/listlab/listprod/director.htm Based on this testing and the requirements of NFPA 37, Sec 4.1.4, the guidelines for installation of the generators listed above are changed to 18 inches (457 mm) from any point of the generator enclosure to a stationary wall, building or structure.
Site Selection and Preparation 3.2.1— Material Sufficient for Level Installation • Dig a rectangular area approximately 5 inches (127 mm) deep and about 6 inches (152 mm) longer and wider than the footprint of the generator. Fill with pea gravel, crushed stone or any other non-combustible material sufficient for level installation. Compact and level the material. A concrete pad can be poured if required.
Section 4 Generator Placement 4.1 — Generator With the Site Selection and Preparation performed, proceed with placement and installation of the generator itself. See Figure 4-1. All air-cooled generators come with a composite pad. The composite pad elevates the generator and helps prevent water from pooling around the bottom. Place the generator (with composite pad) on a concrete pad or four inches (102 mm) of compacted pea gravel. Check local codes to see what type of site base is required.
Generator Placement 4.2 — Fascia Skirt Installation (If Applicable) Install base fascia as follows: 1. Remove four rubber mounts from Owner’s Manual bag. 2. Screw two rubber mounts into threaded holes of end piece. See A of Figure 4-3. 3. Snap end piece into side piece. See B of Figure 4-3. 4. Fit rubber mounts in end piece into lifting holes at base of generator. See C of Figure 4-3. 5. Repeat steps 2-4 to install second end and side pieces. 6.
Section 5 Fuel Conversion/Gas Connections 5.1 — Fuel Conversion Although the generator is configured at the factory for operating on natural gas, provision is made to switch over to LP Vapor. NOTE: The fuel selection (NG/LP) can be changed using the Installation Wizard at initial power up, or by accessing the EDIT Menu thereafter. NOTE: The orange fuel conversion knob is located on the engine at the top of the fuel mixer.
Fuel Conversion/Gas Connections NOTE: All pipe sizing, construction and layout must comply with NFPA 54 for natural gas applications and NFPA 58 for liquid propane applications. Once the generator is installed, verify that the fuel pressure NEVER drops below its required fuel pressure rating. For more information regarding NFPA requirements, refer to www.nfpa.org. Prior to installation, consult local fuel suppliers or the fire marshal for applicable codes and regulations.
Fuel Conversion/Gas Connections 4. When measuring pipe length, add 2.5 feet (0.76m) for each angle or bend in the pipe run and add that to the overall pipe distance. 5.4.1— Natural Gas Pipe Sizing The following table indicates the maximum length (measured in feet / meters) allowed for various pipe sizes. 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 feet (0.
Fuel Conversion/Gas Connections 5.4.3— Gas Installation Summary Mistakes frequently occur when sizing gas pipe. A properly sized gas pipe is critical to the proper operation of the generator. The generator inlet size has no bearing on the proper gas pipe size. If using a piping method other than black pipe, refer to local codes and the pipe manufacturer’s specifications for sizing and installation information. IMPORTANT: Size the gas supply and pipe at 100% Load BTU / megajoule rating. 5.
Fuel Conversion/Gas Connections Sediment Trap Figure 5-3. Sediment Trap Figure 5-4. Incorrect Routing of Flexible Hose 5. When connecting the gas line to the generator, use the provided section of UL Listed or AGA-approved flexible fuel line in accordance with local regulations. The flexible fuel line ensures that vibration from the generator does not cause a gas leak at one of the connection points. It is important that the line be installed with as few bends as possible.
Fuel Conversion/Gas Connections 8. Check gas pressure at the generator fuel pressure regulator as follows: – Close gas supply valve. – Remove top test port from fuel pressure regulator. – Install gas pressure tester (manometer). See Figure 5-5. – Open gas supply valve. – Verify that fuel pressure is within specification. – Close gas supply valve. Top Gas Pressure Test Port Fuel Pressure Regulator Gas Pressure Manometer Figure 5-5.
Fuel Conversion/Gas Connections Check Distance with LP Provider BTU and Pressure Decal Check Distance with Regulator Manufacturer Primary Fuel Pressure Regulator Per LP Provider Manual Shut Off Valve Secondary Fuel Pressure Regulator Flexible Fuel Line Fuel Tank Sediment Trap Manual Shut Off Valve Size Fuel Tank Large Enough to Provide Required BTUs for Generator and ALL Connected Appliance Loads. Be Sure to Correct for Weather Evaporation.
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Section 6 Electrical Connections 6.1 — Generator Connections NOTE: Wiring must be performed in accordance with local jurisdiction and codes. 1. Remove the appropriate Main AC/Control Wiring knock-out plug at back of generator. 2. Install the generator feeder and control wiring between the generator and inverter or electrical loads to be powered by the generator per the applicable NEC codes for the wiring method selected.
Electrical Connections 4-6 AWG: 35 in-lbs (4 Nm) 8 AWG: 25 in-lbs (2.8 Nm) 10-14 AWG: 20 in-lbs (2.3 Nm) Large Ground 2/0 to 14 AWG: 120 in-lbs (14 Nm) Figure 6-1. Control Wiring Torque Specifications NOTE: To separate low voltage from high voltage wires, unless NEC Section 300.3(c)(1) requirements are met, run 2wire start, N1, N2, and T1 wires through wire shielding provided (see Subsection 2.4 —Parts Shipped Loose).
Electrical Connections 6.3 — Main AC Wiring Figure 6-3. Main AC Wiring NOTE: Main AC (E1, E2 and Neutral) wiring must be in accordance with local jurisdiction and codes. 1. Strip insulation from wire ends. Do not remove excessive insulation. 2. Remove two cap plugs located behind the breaker door and to the right of the Main Breaker. 3. Loosen the lugs of the Main Breaker through the access holes. 4. Insert a power wire (E1 or E2) through the opening in the back cover and into the bottom lug.
Electrical Connections NOTE: The AVR cooling air inlet includes a filter. Verify the filter is installed and properly seated at time the unit is installed. Check the filter at regular maintenance intervals to verify proper airflow. See the Maintenance section of the Owner’s Manual for details. 6.5 — Battery Requirements Group 26R, 12V, 525 CCA (Minimum CCA). 6.6 — Battery Installation Proceed as follows: 1. Verify that the generator is turned OFF.
Section 7 Operation 7.1 — Control Pad * The control pad is intended for use by qualified service personnel only. See Figure 7-1. The control pad is located under the lid of the enclosure. The lid is secured by two locks, one on each side of the enclosure. For best results, press down on the lid directly above the side lock, and while holding the lid down, use key to unlock the latch. Repeat step on opposite side of enclosure.
Operation * With the control pad set to AUTO, the engine may crank and start at any time without warning. To prevent possible injury that might occur during sudden starts, always set the control pad to OFF and remove the 7.5 amp fuse before working on or around the generator or the electrical loads that are to be powered by the generator. For added security, place a DO NOT OPERATE tag or placard at both the control pad and the electrical loads that are to be powered by the generator.
Operation 7.3 — 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. If an active alarm/warning condition occurs, the associated Alarm/Warning message is displayed. To clear the Alarm/Warning message, press OFF on the control pad followed by ENTER.
Operation 7.7 — Before Initial Start-Up NOTE: This unit has been run and tested at the factory prior to shipment and does not require any break-in. * Operating the engine with the oil level below the ADD mark on the dipstick can cause engine damage. NOTE: This unit comes filled with 5W - 30 full synthetic oil from the factory. Check the oil level and add the appropriate viscosity and amount if necessary. 7.7.
Installation Guidelines for Air-Cooled Generators ESC ESC ESC ESC Æ NG or LP Æ 2/12/13 12:22 Å Press Enter Æ Æ Firmware Update Å Current Date/Time Å Fuel Selection English - 14 + Insert USB Æ Firmware Update Å ESC ESC Language ESC ENTER ENTER Language ESC + Francais - Possible Message(s) Corrupted File Invalid File File Not Found Unsupported Device - 0 + Select Min (0-59) - + EDIT MAINT ENTER - + DEALER ESC SUB MENUS ENTER HISTORY BATTERY DATE/TIME ESC Switched
Operation 7.7.2— Before Starting Complete the following: 1. Verify that the generator is OFF. A red LED illuminates to confirm that system is in OFF mode. 2. Move the Generator Disconnect Circuit Breaker switch to the OFF (Open) position. 3. Turn off all circuit breakers/electrical loads that are to be powered by the generator. 4. Check engine oil level. If necessary, add oil until the level is at or near the FULL mark on the dipstick. DO NOT OVERFILL. 5. Check fuel supply.
Operation 6. Close the disconnect switch if the appropriate voltage and frequency are present. 7. Check voltage and frequency at the Alternative Power Management System by closing the breakers one at a time (if applicable). 8. Allow the generator to run under load for 20-30 minutes while checking for unusual noises, vibration or other indications of abnormal operation, such as oil leaks or overheating. 9.
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Section 8 Troubleshooting 8.1 — Engine Troubleshooting Table 8-1. Engine Diagnostics Problem Engine will not crank. Cause Correction 1) Fuse blown. 1) Correct short circuit condition by replacing 7.5 Amp fuse. 2) Loose, corroded or defective battery cables. 3) Defective starter contact. 4) Defective starter motor. 5) Dead Battery. 2) Tighten, clean or replace as necessary.* Engine cranks but will not start. 1) Out of fuel. 2) Defective fuel solenoid (FS). 3) Defective spark plug(s).
Troubleshooting 8.2 — Generator Troubleshooting Table 8-2. Generator Diagnostics Active Alarm NONE LED GREEN Problem Things to Check Solution Unit running in AUTO but no power in house. Check Generator Disconnect circuit breaker. Contact servicing dealer if Generator Disconnect circuit breaker is in the ON position. HIGH TEMPERATURE RED Unit shuts down during operation. Check the LEDs/Screen for alarms. Check ventilation around the intake, exhaust and rear of generator.
Troubleshooting Table 8-2. Generator Diagnostics (Continued) Active Alarm Things to Check LED Problem STEPPER OVERCURRENT RED Unit will not start in AUTO with 2wire start signal. Check the LEDs/Screen for alarms. Contact servicing dealer. MISWIRE RED Unit will not start in AUTO with 2wire start signal. Check the LEDs/Screen for alarms. Contact servicing dealer. OVERVOLTAGE RED Unit will not start in AUTO with 2wire start signal. Check the LEDs/Screen for alarms. Contact servicing dealer.
Troubleshooting 8.3 — G-Flex™ Troubleshooting Table 8-3. G-Flex™ Diagnostics Ecode/Active Alarm LED 1048 VSCF Overload RED Unit shuts down during operation. Check the LEDs/Screen for alarms. Alternator, AVR or wiring is damaged. Contact servicing dealer. 1049 VSCF Overload RED Unit shuts down during operation. Check the LEDs/Screen for alarms. Generator output is shorted or severely overloaded. Identify and clear the overload, and then restart. Yellow LED illumi- Check the nated in any state.
Troubleshooting Table 8-3. G-Flex™ Diagnostics (Continued) Ecode/Active Alarm LED Problem Things to Check Possible Causes/Solution 1057 VSCF Overvoltage RED Unit shuts down during operation or starting. Check the LEDs/Screen for alarms. Probable causes are: 1) The generator has been overloaded. Remove load and attempt to restart unit. 2) Generator has started into a severe load. Manually operate generator breaker and try to restart unit.
Troubleshooting Table 8-4. G-Flex™ Diagnostics (Continued) Symptom Possible Causes Generator stalls when large load is supplied. Total load is too big for the generator. Loads must be less than 10 kW or 2 hp when operating under 3600 rpm.Contact installing dealer to correct installation. Output voltage is low/high. Voltage calibration incorrect. Contact servicing dealer. Generator does not pull full power. Current calibration incorrect. Contact servicing dealer.
Section 9 Accessories 9.1 — Descriptions NOTE: Contact an independent Authorized Dealer for additional information on accessories. Table 9-1. Accessories Accessory Description Cold Weather Kit Required in areas where temperatures regularly fall below 32 º F (0 º C). Scheduled Maintenance Kit Includes all pieces necessary to perform maintenance on the generator along with oil recommendations.
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Installation Guidelines for Air-Cooled Generators 732.5 [28.8] LEFT SIDE VIEW 642 [25.3] 637.6 [25.1] 76.2 [3.0] PEA GRAVEL MINIMUM FRONT VIEW 1226 [48.3] 1229.5 [48.4] “DO NOT LIFT BY ROOF” Ø30.2 [ Ø1.2] LIFTING HOLES 4 CORNERS 560.0 [22.0] RIGHT SIDE VIEW 16.0 [5/8] DIA. CLEARANCE HOLE (2) PLACES, 3/8 DIA. MASONRY ANCHOR BOLTS RECOMMENDED HOLE LOCATIONS FOR OPTIONAL MOUNTING TO A CONCRETE PAD 10.0 [3/8] DIA. CLEARANCE HOLE (2) PLACES, 3/8 DIA.
48 DC DISTRIBUTION PANEL 12V/24V/48V AC DISTRIBUTION PANEL 120/240V *House Loads must be less than 10 kW or 2 hp HOUSE LOADS* HOUSE LOADS* 120V/240V CHARGER SUPPLY TWO-WIRE START BATTERY 12V/24V/48V INVERTER TWO-WIRE START ENGINE START BATTERY CHARGER 12 VOLT ENGINE START BATTERY ENGINE CONTROLLER BATTERY VOLTAGE SENSING TWO-WIRE START VOLTAGE REGULATOR (AVR) GENERATOR BATTERY CHARGER ALTERNATOR INVERTER/CHARGER 120/240V OUTPUT ECOGEN - TYPICAL OFF-GRID APPLICATION SYSTEM DIAGRAM HOUS
OIL DIPSTICK AND FILL VENT HOSE Installation Guidelines for Air-Cooled Generators ENGINE-OUT HOSE ENGINE-IN HOSE (TO OIL PUMP) OIL MAKE UP SYSTEM SCHEMATIC (NOT TO SCALE) COOLER-IN HOSE COOLER-OUT HOSE Installation Diagrams 10.
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Part No. 0K6047 Rev. C 01/16/2015 Printed in USA © Generac Power Systems, Inc. All rights 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) generac.