Owner’s Manual 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 installation manual. To locate in Spanish, go to http://www.generac.com/service‐support/product‐support‐lookup To locate in French, go to http://www.
Use this page to record important information about your generator set. Record the information found on your unit data label on this page for quick and easy reference. The label is affixed to the inside partition left of the control pad. For directions on how to open the lid and remove the front panel, see Section 3 Operation.
Table of Contents Table of Contents Section 1 Safety 1.1 Introduction .......................................................................................................................... 1 1.2 General Safety ...................................................................................................................... 2 1.3 General Safety Hazards ....................................................................................................... 2 1.4 Exhaust Hazards ......................
Table of Contents 3.6 USB Port for Firmware Updates ........................................................................................13 3.7 Side Door Compartment ....................................................................................................15 3.7.1 LED Indicators ............................................................................................................................ 15 3.7.2 120V GFCI Outlet/15 Amp Breaker ....................................................
Table of Contents Section 5 Troubleshooting 5.1 Engine Troubleshooting .................................................................................................... 31 5.2 Generator Troubleshooting ............................................................................................... 32 5.3 G-Flex™ Troubleshooting ................................................................................................. 34 Section 6 Installation Diagrams 6.1 Installation Drawing ....................
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Section 1 Safety 1.1 — Introduction Thank you for purchasing this compact, high performance, variable speed, air-cooled, engine-driven stationary automatic standby generator set. Every effort was made to ensure that the information and instructions in this manual was both accurate and complete at the time it was released. However, the manufacturer reserves the right to change, alter, or otherwise improve this product at any time without prior notice.
Safety * $ ! + This symbol points out important Safety Information that, if not followed, could endanger personal safety and/or property of others. This symbol points out a potential Explosion Hazard. This symbol points out a potential Fire Hazard. This symbol points out a potential Electrical Shock Hazard. These “Safety Alerts” cannot eliminate the hazards that they signal. Strict compliance with these special instructions, plus common sense are major accident prevention measures. 1.
Safety • The engine exhaust fumes contain carbon monoxide, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. DO NOT alter or add to the exhaust system or do anything that might render the system unsafe or in noncompliance with applicable codes and standards. • Install a carbon monoxide alarm indoors, according to manufacturer’s instructions/recommendations.
Safety 1.6 — Fire Hazards • For fire safety, the generator must be installed and maintained properly. Installation MUST always comply with applicable codes, standards, laws, regulations and product Installation Manual guidelines. Adhere strictly to local, state, and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established.
Section 2 General Information 2.1 — EcoGen Operating Principle 2.1.1— Benefits The 15 kW EcoGen generator brings exciting new technology to the Home Standby generator product. The generator is significantly more fuel efficient than constant speed generators at normal loads, provides premium power quality, and is significantly quieter while operating at normal loads. • Quieter operation - 3 dB with improved tonal qualities under normal loads • Cleanest Standby power available with 1.
General Information 2.1.6— Large Load (Not Overload) The engine always runs at a speed appropriate for the attached load. Typical loads up to 10 kW or 2 hp can be wired directly. The engine speed remains at 3600 RPM for a programmable time (20 minutes default) and then ramps down to the speed appropriate for the attached load. The programmable time can be changed by the dealer to prevent annoying ramps up and down in engine speed if large loads turn on and off frequently.
General Information 2.3 — Protection Systems The owner/operator is alerted to Alarm and/or Warning conditions via the control pad LCD screen. All Alarm conditions cause the generator to shut down. The Warning messages alert the operator to conditions that do not disable the unit, require immediate correction, or result in shut down. Some of the possible Alarm/Warning messages are listed below. NOTE: For EcoGen specific alarms, see Subsection 5.3 — G-Flex™ Troubleshooting. 2.3.
General Information 2.5 — Specifications 2.5.1— Generator Model 15 kW EcoGen Rated Voltage 240 Rated Maximum Load Current (Amps) at 240 Volts (LP)* 62.5 Main Circuit Breaker 65 Amp Phase 1 Rated AC Frequency 60 Hz Battery Requirement Group 26R, 12 Volts and 525 CCA Minimum (Generac Part No. 0H3421S) Unit Weight in Lbs.
General Information 2.5.3— Fuel Requirements The engine has been fitted with a dual fuel carburetion system. The unit will run on natural gas or LP gas (vapor), but it has been factory set to run on natural gas. The fuel system is configured for the selected fuel source during installation. Recommended fuels should have a btu content of at least 1,000 Btus per cubic foot (37.26 megajoules per cubic meter) for natural gas, or at least 2,500 Btus per cubic foot (93.
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Section 3 Operation 3.1 — Control Pad * The control pad is intended for use by qualified service personnel only. See Figure 3-1. 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 the control pad and the electrical loads that are to be powered by the generator.
Operation 3.3 — 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.
14 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 to “OFF” Hours of Protection 0 (H) SYSTEM +
Operation 3.7 — Side Door Compartment Check local codes for side door locking requirements. A hasp is provided, so that the side door can be secured with a customer supplied padlock if necessary. LED Indicators 15 Amp Outlet Breaker GFCI BREAKER ON ON OFF ON OFF ON ON OFF OFF OFF GENERATOR DISCONNECT 120 GFCI Outlet Generator Disconnect Circuit Breaker Figure 3-4. Open Side Door Compartment 3.7.1— LED Indicators • Green Ready LED: Illuminates when the control pad is set to AUTO.
Operation 3.8 — Battery Charger NOTE: The battery charger is integrated into the control module. 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 screen when the battery needs service.
Section 4 Maintenance 4.1 — Maintenance NOTE: Proper maintenance is necessary for safe operation and is crucial to the life of the generator. Genuine Generac parts MUST be used to ensure warranty coverage NOTE: Since most maintenance alerts occur at the same time (500 or 1000 hour intervals), only one will appear at any one time. Clearing one will cause the next active alert to be displayed. 4.
Maintenance Table 4-1.
Maintenance 4.5.1— Check Enclosure Louvers 1. Verify that intake and exhaust louvers and openings are clean and unobstructed. 2. Wipe exterior surfaces clean using a damp cloth. 3. Loosen dirt, oil, etc. with a soft bristle brush. 4. Remove loose dirt and debris using a vacuum cleaner, or low pressure compressed air (not exceeding 25 psi). NOTE: Periodically wash and wax enclosure using automotive type products. Frequent washing is recommended in salt water/coastal areas. 4.5.
Maintenance 4.5.3.1— Engine Oil Recommendations All oil should meet minimum American Petroleum Institute (API) Service Class SJ, SL or better. Use no special additives. See B of Figure 4-1. Select the oil viscosity grade according to the expected operating temperature. • Above 32° F (0° C), use SAE 30 • Between 40° F and -10° F (4° C and -23° C), use 10W-30 • For all temperature ranges, use Synthetic 5W-30 4.
Maintenance 2. Install battery positive cable (red) to battery positive (+) terminal. 3. Install battery negative cable (black) to battery negative (-) terminal. 4.6.2— Replace AVR Filter + The secondary 12V DC 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 exercise caution when working near the AVR fan housing. + The AVR remains charged for up to three minutes after power down.
Maintenance 7 *1, 2, and 6 4 3 1 **3, 4, and 7 5 6 2 Figure 4-3. Exploded View – EcoGen Oil System Drain Pump Kit EcoGen Oil System Drain Pump Kit Parts List (Kit Part No. 0K3717) 1. ¼ in. Rubber Hose* 2. ½ in. Spring Clamp* 3. ¾ in. Spring Clamp** 4. ½ in. Rubber Hose** 5. Drill Pump 6. ¼ in. Barb Hose Fitting w/¾ in. Hose Thread* 7. ½ in. Barb Hose Fitting w/¾ in. Hose Thread** * Parts 1, 2, and 6 come assembled from the supplier. ** Parts 3, 4, and 7 come assembled from the supplier.
Maintenance A B Figure 4-4. Pump Assembly EcoGen Oil Change Procedure 1. Ensure the engine is up to operating temperature by operating the unit for a minimum of 20 minutes. 2. Press the Control Panel OFF button to shut down the engine. 3. Allow the oil to settle for 10 minutes. NOTE: Allowing the engine to run at operating temperature ensures that the engine oil becomes viscous enough to be drawn out of the system.
Maintenance Figure 4-6. 8. Insert the ¼ in. hose free end into the unit’s oil tank. See Figure 4-7. Figure 4-7. 9. Insert the ½ in. hose free end in to a suitable oil catch container. See Figure 4-8. Figure 4-8.
Maintenance 10. Spin the pump on the high speed setting of the drill. 11. Ensure there are no kinks or obstructions in either hose. NOTE: It may take up to 2 minutes to prime the pump. 12. After oil has begun to be pumped, allow the pump to draw out as much oil as possible to ensure all the oil is removed. 13. A total of 2.5 (2.37L) to 3.5 (3.31L) quarts of oil should be removed from the system. 14. Remove the ¼ in. hose from the tank and allow the drain pump to drain the oil out of it. 15.
Maintenance A B Figure 4-10. Replace Engine Air Filter 4.7.2— Clean/Gap/Replace Spark Plugs Clean, gap or replace spark plugs as follows: + Never disconnect a spark plug with the engine running. Doing so will result in an electric shock that could result in death or serious injury. + The AVR remains charged for up to three minutes after power down. To avoid potential electric shock, allow five minutes to elapse before removing AVR filter housing. 1.
Maintenance 6. Clean spark plugs using a wire brush and commercial solvent. Do not blast spark plugs. Use new spark plugs if necessary. 7. See Figure 4-11. Check spark plug gap using a wire feeler gauge. Adjust gap by carefully bending ground electrode to 1.02 mm (0.040 in). 8. Finger tighten spark plugs into cylinder head, and then using a spark plug socket, tighten to 15-18 ft-lbs (20-25 Nm). 9. Install spark plug cables onto spark plug terminals. 10. Install AVR filter housing.
Maintenance 7. Remove spark plugs from cylinder head using a 5/8 inch spark plug socket. 8. Remove four screws to release valve cover. 9. Move piston to Top Dead Center (TDC) of compression stroke (both valves closed). Proceed as follows: a. Remove intake screen at front of engine to gain access to flywheel nut. b. Place large socket and socket wrench on flywheel nut and rotate engine in a clockwise direction while watching piston through spark plug hole.
Maintenance 10. Install the AVR. Verify that AVR bracket hooks properly engage bottom openings in AVR housing and that the wires below are clear of any hot exhaust components. Start two screws to fasten AVR brackets to back panel. Alternately torque to 50-96 in-lbs (6-11 Nm). 11. Connect 20-pin connector to AVR. Press pin and socket halves together until external latch engages. 12.
Maintenance 12. Remove battery charger AC input T1/Neutral cable (with white sleeve). 13. Attach tag to engine indicating the viscosity and classification of the oil added to the oil tank. 14. Remove spark plugs. Spray a fogging agent into the spark plug holes. Reinstall spark plugs. For more information, see Subsection 4.7.2—Clean/Gap/Replace Spark Plugs. 15. Remove battery and store in a cool, dry room on a wooden board. Never store the battery on a concrete or earthen floor. 16.
Section 5 Troubleshooting 5.1 — Engine Troubleshooting Table 5-1. 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 5.2 — Generator Troubleshooting Table 5-2. Generator Alarm 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 5-2. Generator Alarm Diagnostics (Continued) Active Alarm Things to Check LED Problem 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. LOW BATTERY YELLOW Yellow LED illuminated in any state. Check screen for additional information. Clear alarm.
Troubleshooting 5.3 — G-Flex™ Troubleshooting Table 5-3. G-Flex™ Ecode 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.
Troubleshooting Table 5-3. G-Flex™ Ecode 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 5-4. G-Flex™ Diagnostics 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.
732.5 [28.8] EcoGen Automatic Standby Generator Owner’s Manual 76.2 [3.0] PEA GRAVEL MINIMUM LEFT SIDE VIEW 642 [25.3] 637.6 [25.1] FRONT VIEW 1226 [48.3] 1229.5 [48.4] "DO NOT LIFT BY ROOF" 30.2 [ 1.2] LIFTING HOLES 4 CORNERS 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 560.0 [22.0] 10.0 [3/8] DIA. CLEARANCE HOLE (2) PLACES, 3/8 DIA.
38 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 EcoGen Automatic Standby Generator Owner’s Manual 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 6.
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Part No. 0K6046 Rev. A 09/09/2014 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.
