Generac Power Systems 15 kW EcoGen Owner's Manual

Owner’s Manual

000918

(000209a)

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.

60 Hz Air-Cooled Generators

15 kW EcoGen™

WWW.GENERAC.COM

1-888-GENERAC

(888-436-3722)

Para español, visita: http://www.generac.com/service-support/product-support-lookup

Pour le français, visiter : http://www.generac.com/service-support/product-support-lookup

SAVE THIS MANUAL FOR FUTURE REFERENCE

Use this page to record important information about your generator set.

Model:

Serial:

Prod Date Week:

Volts:

LPV Amps:

NG Amps:

Hz:

Phase:

Controller P/N:

(000005)

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.

(000004)

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.

Record the information found on your unit data label on this page. See General Information for the location of the unit data label. The unit has a label plate affixed to the inside partition, to the left of the control panel console as shown in

Figure 2-1. See Operation for directions on how to open the

top lid and remove the front panel.

When contacting an Independent Authorized Service Dealer (IASD) about parts and service, always supply the complete model and serial numbers of the unit.

Operation and Maintenance: Proper maintenance and care of the generator ensures a minimum number of problems and keeps operating expenses at a minimum. It is the operator’s responsibility to perform all safety checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment checked periodically by an IASD. Normal maintenance, service, and replacement of parts are the responsibility of the owner/ operator and are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage may contribute to the need for additional maintenance or service.

When the generator requires servicing or repairs, Generac recommends contacting an Independent Authorized Service Dealer for assistance. Authorized service technicians are factory–trained and are capable of handling all service needs.To locate the nearest Independent Authorized Service Dealer, please visit the dealer locator at:

www.generac.com/Service/DealerLocator/

ii Owner’s Manual for 60 Hz EcoGen™? Generators

Section 1: Safety Rules & General

Information

Introduction ..........................................................1

Read This Manual Thoroughly ....................................1

Safety Alerts .........................................................1

How to Obtain Service .................................................1

Safety Rules .........................................................2

General Hazards .........................................................2

Exhaust Hazards .........................................................3

Electrical Hazards .......................................................3

Fire Hazards ................................................................4

Explosion Hazards ......................................................4

Section 2: General Information

EcoGen Operating Principle ...............................5

Benefits .......................................................................5

How It Works ...............................................................5

Startup .........................................................................5

Normal Running ..........................................................5

Small Load Changes ...................................................5

Large Load (Not Overload) ..........................................5

Automatic Voltage Regulator (AVR) Cooling Fans ......5

The Generator ......................................................6

Specifications ......................................................7

Generator ....................................................................7

Engine .........................................................................7

Protection Systems .............................................8

Emission Information ..........................................8

Fuel Requirements ..............................................8

Battery Requirements .........................................8

Battery Charger ....................................................8

Engine Oil Requirements ....................................8

Activating the Generator .....................................9

Replacement Parts ..............................................9

Accessories ..........................................................9

Section 3: Operation

Site Prep Verification .........................................11

Generator Enclosure .........................................11

Opening the Lid .........................................................11

Intake Side Panel Removal .......................................12

Main Line Circuit Breaker (Generator Disconnect) ....12

LED Indicator Lights ..................................................12

Control Panel Interface ..................................... 13

USB Port for Firmware Updates ................................13

Using the AUTO/OFF/MANUAL Interface ........ 13

Interface Menu Displays ................................... 13

The LCD Panel .......................................................... 13

Menu System Navigation .......................................... 14

Battery Charger ................................................. 16

Automatic Sequence of

Operation ........................................................... 16

Cranking ....................................................................16

Cold Smart Start ........................................................ 16

Shutting Generator Down While Under Load Or

During An Extended Run .................................. 16

To turn the generator OFF (while running in AUTO and

online): ......................................................................16

To turn the generator back ON: .................................16

Section 4: Maintenance

Maintenance ....................................................... 23

Preparing for Maintenance ............................... 23

Performing Scheduled Maintenance ............... 23

Maintenance Log ............................................... 24

Checking Engine Oil Level ............................... 25

Engine Oil Requirements .......................................... 25

Changing the Oil and Oil Filter ......................... 26

EcoGen Oil System Drain Pump Kit Parts List ..........26

EcoGen Oil System Drain Pump Assembly ..............26

EcoGen Oil Change Procedure .................................27

Replacing the Engine Air Filter ........................ 28

Replacing the AVR Filter .................................. 28

Maintaining the Spark Plugs ............................ 29

Valve Clearance Adjustment ............................ 29

Check Valve Clearance ............................................. 29

Adjust Valve Clearance .............................................30

Battery Maintenance ......................................... 31

Cleaning the Sediment Trap ............................. 31

Attention After Submersion .............................32

Owner’s Manual for 60 Hz EcoGen™ Generators iii

Table of Contents

Corrosion Protection ......................................... 32

Remove From, and Return To

Service Procedure .............................................32

Remove From Service .............................................. 32

Return to Service ...................................................... 32

Section 5: Troubleshooting / Quick

Reference Guide

Generator Troubleshooting ..............................35

Quick Reference Guide .....................................36

AVR Troubleshooting ........................................ 38

AVR Diagnostics ................................................40

iv Owner’s Manual for 60 Hz EcoGen™ Generators

Safety Rules & General Information

(000100a)

WARNING

Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.

(000001)

DANGER

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

(000002)

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

(000003)

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Section 1: Safety Rules & General Information

Introduction

Thank you for purchasing this compact, high performance, air-cooled, engine-driven generator. It is designed to automatically supply electrical power to operate critical loads during a normal power source failure.

As supplied from the factory, this generator is designed to work in off-grid applications.

In off-grid applications as a part of an alternative energy system, the generator starts when the inverter/battery charger detects the normal power source voltage has dropped below a preset level. The generator powers the inverter, and once the voltage level of the normal power source rises to an acceptable level, the generator is shut down. Another off-grid application would be for use in remote locations such as for pumping water for a village or campground, or for livestock.

The unit is factory installed in an all-weather metal enclosure and is intended for outdoor installation only. The generator can be operated using either natural gas (NG) or vapor withdrawn liquid propane (LP).

NOTE: When sized properly, this generator is suitable for supplying typical residential loads such as induction motors (sump pumps, refrigerators, air conditioners, furnaces, etc.), electronic components (computer, monitor, TV, etc.), lighting loads and microwaves, or loads less than 10 kW or 2 hp.

The information in this manual is accurate based on products produced at the time of publication. The manufacturer reserves the right to make technical updates, corrections, and product revisions at any time without notice.

Read This Manual Thoroughly

If any portion of this manual is not understood, contact the nearest Independent Authorized Service Dealer (IASD) for starting, operating, and servicing procedures.

This manual must be used in conjunction with the appropriate installation manual.

SAVE THESE INSTRUCTIONS: The manufacturer suggests that this manual and the rules for safe operation be copied and posted near the unit installation site. Safety should be stressed to all operators and potential operators of this equipment.

Owner’s Manual for 60 Hz EcoGen™ Generators 1

Safety Alerts

Throughout this publication and on tags and decals affixed to the generator, DANGER, WARNING, and CAUTION blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:

NOTE: Notes provide additional information important to a procedure or component.

These safety alerts cannot eliminate the hazards they indicate. Observing safety precautions and strict compliance with the special instructions while performing the action or service are essential to preventing accidents.

The operator is responsible for proper and safe use of the equipment. The manufacturer strongly recommends that if the operator is also the owner, to read the owner’s manual and thoroughly understand all instructions before using this equipment. The manufacturer also strongly recommends instructing other users to properly start and operate the unit. This prepares them if they need to operate the equipment in an emergency.

How to Obtain Service

Contact an IASD for assistance when the generator requires servicing or repairs. Service technicians are factory-trained and are capable of handling all service needs. Please visit the dealer locator at:

www.generac.com/Service/DealerLocator/ to locate

the nearest IASD.

When contacting a dealer about parts and service, always supply the complete model and serial numbers of the unit as given on its data plate (decal), which is

Safety Rules & General Information

DANGER

Accidental start-up. Disconnect power and render unit inoperable before performing service work. Failure to do so will result in death or serious injury.

(000344)

(000190)

DANGER

Loss of life. Property damage. Installation must always comply with applicable codes, standards, laws and regulations. Failure to do so will result in death or serious injury.

(000209a)

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.

WARNING

This unit is not intended for use as a prime power source. It is intended for use as an intermediate power supply in the event of temporary power outage only. See individual unit specifications for required maintenance and run times pertaining to use.

(000247)

(000130)

WARNING

Accidental Start-up. Disconnect the negative battery cable, then the positive battery cable when working on unit. Failure to do so could result in death or serious injury.

(000182)

WARNING

(000187)

WARNING

(000155)

WARNING

Only a trained and licensed electrician should perform wiring and connections to unit. Failure to follow proper installation requirements could result in death, serious injury, and damage to equipment or property.

(000115)

WARNING

Moving Parts. Do not wear jewelry when starting or operating this product. Wearing jewelry while starting or operating this product could result in death or serious injury.

(000111)

WARNING

Moving Parts. Keep clothing, hair, and appendages away from moving parts. Failure to do so could result in death or serious injury.

(000108)

WARNING

Hot Surfaces. When operating machine, do not touch hot surfaces. Keep machine away from combustibles during use. Hot surfaces could result in severe burns or fire.

(000146)

WARNING

Equipment and property damage. Do not alter construction of, installation, or block ventilation for generator. Failure to do so could result in unsafe operation or damage to the generator.

located on the generator. See Figure 2-1 for decal location. Record the model and serial numbers in the spaces provided on the inside front cover of this manual.

Safety Rules

Study these SAFETY RULES carefully before installing, operating, or servicing this equipment. Become familiar with this owner’s manual and with the unit. The generator can operate safely, efficiently, and reliably only if it is properly installed, operated, and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The alerts in this manual and on tags and decals affixed to the unit are not all-inclusive. If using a procedure, work method, or operating technique the manufacturer does not specifically recommend, verify that it is safe for others and does not render the generator unsafe.

General Hazards

2 Owner’s Manual for 60 Hz EcoGen™ Generators

Safety Rules & General Information

WARNING

Risk of injury. Do not operate or service this machine if not fully alert. Fatigue can impair the ability to service this equipment and could result in death or serious injury.

(000215)

WARNING

Environmental Hazard. Always recycle batteries at an official recycling center in accordance with all local laws and regulations. Failure to do so could result in environmental damage, death or serious injury.

(000228)

WARNING

Injury and equipment damage. Do not use generator as a step. Doing so could result in falling, damaged parts, unsafe equipment operation, and could result in death or serious injury.

(000216)

Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury.

(000103)

DANGER

(000178a)

Asphyxiation. Always use a battery operated carbon monoxide alarm indoors and installed according to the manufacturer’s instructions. Failure to do so could result in death or serious injury.

WARNING

(000146)

WARNING

Equipment and property damage. Do not alter construction of, installation, or block ventilation for generator. Failure to do so could result in unsafe operation or damage to the generator.

(000144)

DANGER

Electrocution. Contact with bare wires, terminals, and connections while generator is running will result in death or serious injury.

(000150)

DANGER

Electrocution. Never connect this unit to the electrical system of any building unless a licensed electrician has installed an approved transfer switch. Failure to do so will result in death or serious injury.

(000188)

DANGER

Electrocution. Do not wear jewelry while working on this equipment. Doing so will result in death or serious injury.

(000104)

DANGER

Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury.

(000145)

DANGER

Electrocution. In the event of electrical accident, immediately shut power OFF. Use non-conductive implements to free victim from live conductor. Apply first aid and get medical help. Failure to do so will result in death or serious injury.

Electrical Hazards

DANGER

Electrical backfeed. Use only approved switchgear to isolate generator from the normal power source. Failure to do so will result in death, serious injury, and equipment damage.

(000237)

• Inspect the generator regularly, and contact the

nearest IASD for parts needing repair or replacement.

Exhaust Hazards

DANGER

Electrocution. Verify electrical system is properly grounded before applying power. Failure to do so will result in death or serious injury.

(000152)

The generator must be installed and operated

•

outdoors only.

Owner’s Manual for 60 Hz EcoGen™ Generators 3

Safety Rules & General Information

WARNING

Fire hazard. Do not obstruct cooling and ventilating airflow around the generator. Inadequate ventilation could result in fire hazard, possible equipment damage, death or serious injury.

(000217)

WARNING

Fire and explosion. Installation must comply with all local, state, and national electrical

(000218)

building codes. Noncompliance could result in unsafe operation, equipment damage, death or serious injury.

WARNING

Fire hazard. Use only fully-charged fire

(000219)

extinguishers rated “ABC” by the NFPA. Discharged or improperly rated fire extinguishers will not extinguish electrical fires in automatic standby generators.

(000100a)

WARNING

Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.

WARNING

to use required safety equipment could result in death or serious injury.

(000257)

Electrocution. Refer to local codes and standards for safety equipment required when working with a live electrical system. Failure

(000147)

WARNING

Risk of Fire. Unit must be positioned in a manner that prevents combustible material accumulation underneath. Failure to do so could result in death or serious injury.

(000192)

DANGER

(000151)

DANGER

Connection of fuel source must be done by a qualified professional technician or contractor. Incorrect installation of this unit will result in death, serious injury, and damage to equipment and property damage.

(000174)

DANGER

Risk of fire. Allow fuel spills to completely dry before starting engine. Failure to do so will result in death or serious injury.

(000110)

WARNING

Risk of Fire. Hot surfaces could ignite combustibles, resulting in fire. Fire could result in death or serious injury.

Fire Hazards

Explosion Hazards

Comply with regulations the Occupational Safety

•

and Health Administration (OSHA) has established. Also verify 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.

4 Owner’s Manual for 60 Hz EcoGen™ Generators

Section 2: General Information

(000111)

WARNING

Moving Parts. Keep clothing, hair, and appendages away from moving parts. Failure to do so could result in death or serious injury.

General Information

EcoGen Operating Principle

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 1.5% THD

• Significant fuel savings: more fuel efficient under

normal loads

• Lower operating speed of 2700 rpm at low loads

• Tuned exhaust system to further lower sound levels

• Variable Speed / Constant Frequency operation

How It Works

In an off-grid solution, the generator is an important source of backup power when other resources are insufficient for the demand, improving overall system reliability.

1. Sun (solar cells) and/or wind (turbines) generate

DC current.

2. This is fed to the inverter charger and then on to

the battery bank.

3. The inverter takes DC power from the battery bank,

converts it to AC, and then sends the current to the AC electrical panel.

4. If there is no solar or wind gain and the battery

bank level drops below a preset threshold, the inverter automatically signals the generator to start.

5. The generator feeds AC power to the inverter,

which in turn sends power to the electric panel and recharges the battery bank to an acceptable level.

During startup, as the engine speed increases to 3600 RPM, the Automatic Voltage Regulator (AVR) electronics perform a self test involving an overall system check of the unit. If a fault is detected, the unit shuts down and displays an alarm.

Normal Running

The engine operates between 2700 RPM–3600 RPM depending on the attached load. When the load increases or decreases, the speed increases or decreases accordingly.

Small Load Changes

The system is designed to maintain the current engine speed for small load changes. Larger load changes result in a change in engine speed to appropriately handle the load.

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 decreases to the speed appropriate for the attached load. The programmable time can be changed by the dealer to prevent annoying increases and decreases in engine speed if large loads turn on and off frequently.

If natural gas is the selected fuel type, then all loads up to 9 kW can be wired directly.

Automatic Voltage Regulator (AVR) Cooling Fans

The system is equipped with two fans to cool the AVR electronics. The primary fan is powered by AC during operation. The secondary fan is powered by 12V DC through the controller. The fans are monitored during operation and if a failure occurs, an alarm is displayed.

Startup

When the generator starts, the engine speed gradually increases to 3600 RPM to produce maximum power. This ensures that there is sufficient power to carry the load on start-up. The engine RPM then gradually decreases to a speed appropriate for the attached load.

For example, if there is no load, the engine speed decreases to approximately 2700 RPM. The time it takes to decrease to 2700 RPM is approximately 4–5 minutes. Since the ramp rate is linear, less time would be required for it to decrease to only 3400 RPM.

Owner’s Manual for 60 Hz EcoGen™ Generators 5

The secondary fan continues to operate for up to 80 minutes after the generator is shut down. Proper cooling must occur before removing battery connections for maintenance or other service activity.

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.

General Information

003603

The Generator

Figure 2-1. Components and Control Locations

A. AVR E. Control Panel J. Oil Tank N. Sediment Trap

B. AVR Fil ter F. Battery Compartment

C. Main Line Circuit Breaker (Generator

D. Airbox with Air Cleaner H. Status LED Indicators M. Composite Base R. Lock with Cover

Disconnect)

K. Oil Fill Cap/Oil dip

(Battery not supplied)

G. Exhaust Enclosure L. Oil Filter P.Q.Fuel Inlet

stick

O. Fuel Regulator

Data Plate Location

6 Owner’s Manual for 60 Hz EcoGen™ Generators

General Information

Specifications

Generator

Model 15 kW EcoGen

Rated Voltage 240

Rated Maximum Load Current (Amps) at 240 Volts (LP and NG)*

Main Circuit Breaker 70 Amp

Phase 1

Rated AC Frequency 60 Hz

Battery Requirement

Unit Weight in Lbs. (kilos) 471 (213.6)

Enclosure Aluminum

Normal Operating Range This unit is tested in accordance to UL 2200 standards with an operating

These generators are rated in accordance with UL 2200, Safety Standard for Stationary Engine Generator Assemblies, and CSA-C22.2 No. 100-04 Standard for Motors and Generators.

62.5

12 Volts, Group 26R 540 CCA Minimum or Group 35AGM 650 CCA Minimum

temperature of -20º F (-29º C) to 122º F (50º C). For areas where temperatures fall below 32º F (0º C) a cold weather kit is recommended. When operated above 77º F (25º C) there may be a decrease in engine power. Please reference the engine specifications section.

Engine

Model 15 kW EcoGen

Type of Engine G-Force 1000 Series

Number of Cylinders 2

Displacement 999 cc

Cold Valve Clearance 0.002”-0.004” (0.05 mm - 0.1 mm)

Cylinder Block Aluminum w/Cast Iron Sleeve

Recommended Spark Plug

Spark Plug Gap 0.040 in. (1.02 mm)

Starter 12 VDC

Oil Capacity Including Filter

Recommended Oil Filter Part #070185E

Recommended Air Filter Part #0J8478

Maximum wattage and current is subject to and limited by such factors as fuel BTU/joules content, ambient temperature and altitude. Maximum power decreases about 3.5 percent for each 1,000 feet (304.8 meters) above sea level, and also will decrease about 1 percent for each 10° F (6º C) above 60º F (15º C) ambient temperature.

RC12YC

Approx. 3.75 Quarts / 3.55 Liters

The specification sheet for this generator was included in the documentation provided with the unit at the time of purchase. For additional copies, consult your local Independent Authorized Service Dealer.

Owner’s Manual for 60 Hz EcoGen™ Generators 7

General Information

(000105)

DANGER

Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Add fuel in a well ventilated area. Keep fire and spark away. Failure to do so will result in death or serious injury.

Protection Systems

The generator may need to run for long periods of time with no operator present to monitor the engine/generator conditions. The generator is equipped with protection systems to automatically shut down the unit to protect against potentially damaging conditions. Some of these systems include:

Alarms:

• High Temperature

• Low Oil Pressure

• Overcrank

• Overspeed

• Overvoltage

• Undervoltage

• Underspeed

• RPM Sensor Loss

• Controller Fault

• Wiring Error

• Fuse Problem

• Stepper Overcurrent

• Overload

Warnings:

• Charger Warning

• Charger Missing AC

• USB Warning

• Download Failure

• Low Battery

• Battery Problem

The control panel contains a display which alerts the operator when a fault condition occurs. The above list is not all inclusive. See Operation for more information about alarms and control panel operation.

NOTE: A warning will indicate a condition on the generator that should be addressed, but will not shut the generator down. An alarm will shut the generator down to protect the system from any damage. In the event of an alarm, an owner can clear the alarm and restart the generator prior to contacting an IASD. If the intermittent issue occurs again, contact an IASD.

Emission Information

The United States Environmental Protection Agency (US EPA) (and California Air Resources Board (CARB), for engines/equipment certified to California standards) requires that this engine/equipment complies with exhaust and evaporative emissions standards. Locate the emissions compliance decal on the engine to determine applicable standards. For emissions warranty information, please reference the included emissions warranty. Follow the maintenance specifications in

Maintenance to ensure that the engine complies with the

applicable emissions standards for the duration of the product’s life.

This generator is certified to operate on Liquid Propane Vapor fuel or pipeline Natural Gas.

The Emission Control System code is EM (Engine Modification). The Emission Control System on this generator consists of the following:

System Components

Air Induction

Fuel Metering

Ignition

Exhaust

- Intake Manifold

- Air Cleaner

- Carburetor and Mixer Assembly

- Fuel Regulator

- Spark Plug

- Ignition Module

- Exhaust Manifold

- Muffler

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 will be configured for the available fuel source during installation.

Recommended fuels should have a BTU content of at least 1000 BTUs per cubic foot (37.26 megajoules per cubic meter) for natural gas, or at least 2500 BTUs per cubic foot (93.15 megajoules per cubic meter) for LP gas (vapor).

NOTE: If converting to LP gas from natural gas, a minimum LP tank size of 250 gal (946 L) is recommended. See the installation manual for complete procedures and details.

Battery Requirements

12 volts, Group 26R-540CCA minimum or Group 35AGM650CCA minimum (not included with unit.) See

Maintenance

for proper battery maintenance procedures.

Battery Charger

The battery charger is integrated into the control panel module in all models. It operates as a smart charger, which ensures output charging levels are safe and continuously optimized to promote maximum battery life.

Engine Oil Requirements

See Engine Oil Requirements in the Maintenance section for proper oil viscosity.

8 Owner’s Manual for 60 Hz EcoGen™ Generators

General Information

Activating the Generator

The generator should be activated upon initial start-up. See the installation manual for complete instructions.

Replacement Parts

Description 15 kW EcoGen

26R Exide Battery 0H34215

Spark Plug 0G0767A

Oil Filter 070185E

Air Filter 0J8478

Control Panel Fuse 0D7178T

AVR Air filter 0K3054

Rotor Brushes 0J8318

Accessories

NOTE: Performance enhancing accessories are available for air-cooled generators. Contact an IASD or visit

www.generac.com for additional information on replacement parts, accessories, and extended warranties. See also http://www.ordertree.com/generac/air-cooled-homestandby-generators/.

Accessory Description

Cold Weather Accessories*—

• Battery Pad Warmer

• Oil Warmer

• Breather Warmer

* each sold separately

Scheduled Maintenance Kit Includes all pieces necessary to perform maintenance on the generator along with oil

Touch-Up Paint Kit Very important to maintain the look and integrity of the generator enclosure. This kit includes

Wireless Local Monitor The Wireless Local Monitor is completely wireless and battery powered, and provides owners

• Recommended in areas where temperatures fall below 0 °F (-18 °C).

(Not necessary for use with AGM-style batteries)

• Recommended in areas where temperatures fall below 0 °F (-18 °C).

• Recommended in areas where heavy icing occurs.

recommendations.

touch-up paint and instructions.

with instant generator status updates without ever leaving the house. Status lights (red, yellow, and green) alert owners when the generator needs attention. Magnetic backing permits refrigerator mounting and gives a 600 ft (183 m) line of sight communication.

Owner’s Manual for 60 Hz EcoGen™ Generators 9

General Information

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10 Owner’s Manual for 60 Hz EcoGen™ Generators

Section 3: Operation

Accidental start-up. Disconnect power and render unit inoperable before performing service work. Failure to do so will result in death or serious injury.

(000344)

001797

Operation

Site Prep Verification

The generator must be installed so that airflow into and out of the generator is not impeded. Verify that all shrubs or tall grasses within 3 ft (0.91 m) of the intake and discharge louvers on the sides of the enclosure have been removed. Install the generator on high ground where water levels will not rise and endanger it. This unit should not operate in or be subjected to standing water. Verify that all potential water sources such as water sprinklers, roof run-off, rain gutter downspouts, and sump pump discharges are directed away from the generator enclosure.

DANGER

Generator Enclosure

The lid will be locked. A set of keys is attached to the intake side of the generator.

1. Cut the plastic bag to remove the keys.

2. Use the keys to open the lid of the generator.

NOTE: The enclosed keys provided with this unit are

intended for service personnel use only.

Opening the Lid

Two locks secure the lid—one on each side (A in Figure

3-1). Open the protective rubber cap to access the

keyhole, and press down on the lid above the side lock and unlock the latch to properly open the lid.

Repeat for the other side. The lid may appear stuck if pressure is not applied from the top.

NOTE: Always verify that the side locks are unlocked before attempting to lift the lid.

Removing the Front Access Panel

Remove the front access panel by lifting it straight up and out once the lid is open.

Always lift the front access panel straight up before pulling it away from the enclosure (B and C in Figure 3-

1). Do not pull the panel away from the enclosure before

lifting up (D in Figure 3-1).

Figure 3-1. Side Lock Location and Front Panel Removal

Owner’s Manual for 60 Hz EcoGen™ Generators 11

Operation

002961

001810

001791

Intake Side Panel Removal

See Figure 3-2. The intake side panel (A) must be removed to access the battery compartment, fuel regulator, and sediment trap.

1. Raise the lid and remove the front panel.

2. Use an Allen wrench to remove two mounting

screws (B) and the L-bracket screw (C).

Figure 3-2. Intake Side Panel Removal

Main Line Circuit Breaker (Generator Disconnect)

3. Lift the intake panel up and away from the

generator.

NOTE: Always lift the intake side panel straight up before pulling away from enclosure. Do not pull the panel away from the enclosure before lifting up (D).

LED Indicator Lights

This is a 2-pole breaker rated according to relevant specifications. See “A” in Figure 3-3.

The breaker can be locked in the OFF (OPEN) position for security. Use an appropriately-sized padlock (not included) with a shackle long enough to pass through both lock tabs (B).

Figure 3-3. Main Breaker

NOTE: DO NOT lock out the MLCB during normal generator operation. Doing so will compromise automatic standby functionality.

Figure 3-4. LED Indicator Lights

See Figure 3-4. Three LEDs are visible behind a translucent lens on the generator side panel. These LEDs indicate the operating status of the generator.

• Green LED “Ready” light (A) is illuminated when

the control panel button is in the AUTO position. The LED flashes when the connected load is running under generator power.

• Red LED “Alarm” light (B) is illuminated when the

generator is OFF or a fault is detected. Contact an IASD.

• Yellow LED “Maintenance” light (C) is illuminated

when scheduled maintenance is due.

NOTE: Yellow Maintenance or Warning LED may be on at the same time as either the Red or Green LED.

12 Owner’s Manual for 60 Hz EcoGen™ Generators

Operation

001798

Control Panel Interface

See Figure 3-5. The control panel interface (A) is located under the lid of the enclosure. Verify that both the left and right side locks are unlocked before attempting to lift the lid of the enclosure. Open the lid as directed in Opening

the Lid.

The 7.5A fuse is located beneath the rubber cover (B) to the right of the control panel.

Verify that both the left and right side locks are securely out of the way before closing the unit.

Figure 3-5. Generator Control Panel

Using the AUTO/OFF/MANUAL Interface

Button Description of Operation

This button activates fully automatic system operation. The Green LED on this button will flash if

AUTO

OFF

MANUAL

running in Automatic mode and the connected loads are running under generator power. Transfer to standby power occurs if remote two wire start is ON (CLOSED).

This button shuts down the engine and prevents automatic operation of the unit.

This button cranks and starts the generator. The blue LED on this button will flash if running in manual mode and the connected loads are running under generator power.

NOTE: Damage caused by mis-wiring of the interconnect wires is not warrantable.

Interface Menu Displays

All appropriate panels must be in place during any operation of the generator. This includes operation by a servicing technician while conducting troubleshooting procedures.

USB Port for Firmware Updates

A USB Port is located beneath the rubber cover (B) and is provided for firmware updates. Firmware updates must be performed by an IASD.

NOTE: The USB port is intended for use with a USB flash drive only. The USB port is not intended for charging or powering any device such as phones or LED lights. Do not connect any consumer electronics to the USB port.

The LCD Panel

Feature Description

Default page that is displayed if no buttons are pressed for 60 seconds. Normally shows current status message and the current date and time. The highest priority active alarm/

warning is automatically posted on this page, HOME page

Display Backlight

MAIN MENU page

as well as flashing the backlight when such a

condition is detected. In the case of multiple

alarms/warnings, only the first message will be

displayed. Press the OFF button then enter to

clear an alarm. Warnings are cleared when the

issue is corrected and cannot be cleared with

any button.

Normally off. The backlight will automatically

light and remain on for 30 seconds if the

operator presses any button.

Allows the operator to navigate to all other

pages or sub-menus by using the arrow keys

and the ENTER button. Page can be accessed

at any time with several presses of the

dedicated ESCAPE button. Each press of the

ESCAPE button takes the operator to the

previous menu until the MAIN MENU displays.

This page contains information for - History;

Status; Edit; Debug.

Owner’s Manual for 60 Hz EcoGen™ Generators 13

Operation

ECOGEN HSB MENU MAP

“Run Log”

ESC

ENTER

SYSTEM

BATTERY

DATE/TIME

SUB MENUS

HISTORY

EDIT

Firmware Update



Press Enter



ESC

ENTER

Current Date/Time



2/12/13 12:22



ESC

ENTER

ESC

ENTER

ESC

ENTER

ESC

ENTER

ENTERENTER

ENTER

ESC

Switched to “OFF”

Hours of Protection

0 (H)

Language



English



Fuel Selection



NG or LP



Possible Message(s)

Corrupted File

Invalid File

File Not Found

Unsupported Device

Firmware Update



Insert USB



“Alarm Log”

- Alarm Log +

- Run Log +

- 1 thru 50 +

Warning Message(s)

"Low Battery"

"FIRMWARE ERROR-9"

"Fuel Pressure"

"Battery Problem"

"Charger Warning"

"Charger Missing AC"

"Overload Warning" "Overload Cooldown" "SEEPROM ABUSE"

"USB Warning"

"Download Failure"

Running Manual

Running-Remote Start

Switched Off

Stopped - Auto

Stopped - Alarm

Alarm Message(s)

"High Engine Temp."

"Low Oil Pressure"

"Overcrank"

"Overspeed"

"RPM Sense Loss"

"Underspeed"

"Internal Fault"

"FIRMWARE ERROR-7"

"WIRING ERROR"

"Over Voltage"

"Under Voltage"

"Overload Remove Load"

"Low Volts Remove Load"

"Stepper Over Current"

"Fuse Problem"

ESC

Select Min (0-59)

- 0 +

ESC

Select Hour (0-23)

- 14 +

Language

+ English -

Fuel Selection

+ NG or LP -

Language

+ Espanol -

Language

+ Francais -

Battery Condition

“Good” “Inspect Battery” or “Check Battery”

003602

Menu System Navigation

To get to the MENU, use the ESCAPE button from any page. You may need to press the ESCAPE button several times before reaching the MENU page. Navigate to the desired menu by using the

displayed and flashing, press the ENTER button.

↑/↓ buttons. When the desired menu is

14 Owner’s Manual for 60 Hz EcoGen™ Generators

Figure 3-6. Navigation Menu

UP ARROW =

DOWN ARROW = -

MAINT

DEALER

EXAMPLE:

Inspect Battery 200 RnHr or 12/27/13

and

Next Maintenance 200 RnHr or 12/27/13

Current Date/Time

02/14/13 07:40

ESC

ENTER

ESC ENTER

ESC

ESC ESC

ENTER

ESC

MAINT :

Maint. Log

Run Hrs

Scheduled

Select Month (1-12)

- 2 +

Run Hours (H)

0.0

ENTER

Select Date (1-31)

- 13 +

ENTER

Select Year (0-99)

- 13 +

ENTER

Access Requires Password

"Current:V XXXX "

"USB: V XXXX"

"Are You Sure?"

"- Yes or No +"

ESC

ENTER

ESCENTER

Select “Yes” then Press “Enter” to continue or Press “ESCAPE” to escape out of updating.

During update process the Blue “Manual” light flashes, then the Green “Auto” light flashes. Sequence does this twice. When update is complete the unit returns to Install Wizard menu.

When the controller powers up the very first screen displays the version number for a few seconds.

When update is complete remove Thumb Drive, then follow the Install Wizard Menu.

- 1 thru 50 +

"Battery Maintained" "Schedule A Serviced" "Schedule B Serviced"

"Maintenance Reset"

"Inspect Battery" "Service Schedule A" "Service Schedule B"

Language

+ Portuguese -

001382b

Operation

Figure 3-7. Navigation Menu

Owner’s Manual for 60 Hz EcoGen™ Generators 15

Operation

Battery Charger

NOTE: The battery charger is integrated into the control

module in all models.

The battery charger operates as a smart charger that verifies:

• Will not transfer to generator if MLCB (generator disconnect) is OFF (OPEN).

MANUAL

• Will transfer to generator if MLCB (generator disconnect) is ON (CLOSED).

• Will start and run when remote two-wire start is ON (CLOSED).

AUTO

• The generator will shut down if the OFF button is pressed or a shutdown alarm is present.

• Once remote two-wire start is OFF (OPEN), the generator will shut down immediately (a

selectable cool down is provided; default is no cool down)

Automatic Sequence of Operation

Cranking

The system will control the cyclic cranking as follows:

• 16 second crank, seven (7) second rest, 16 second

crank, seven (7) second rest, followed by three (3) additional cycles of seven (7) second cranks followed by seven (7) second rests.

Cold Smart Start

The Cold Smart Start feature monitors the ambient temperature and adjusts the warm-up delay upon start up in AUTO mode based on prevailing conditions.

The generator will startup with the normal warm-up delay of 5 seconds if the ambient temperature is at or above the fixed temperature.

A check for proper output voltage build up will be performed when the generator engine is started.

If some condition impedes normal voltage creation, such as frost crystals or dust/dirt preventing a good electrical connection, the start sequence will be interrupted so that a cleaning cycle of the internal electrical connections can be attempted.

The cleaning cycle is an extended warming up period which lasts for several minutes while the normal generator voltage output is determined to be low. During this cycle, the generator controller will display “Warming Up” on the display screen.

The generator controller display will show “Under Voltage” if the cleaning cycle fails to clear the obstruction. After several minutes, the alarm message can be cleared, and the generator restarted.

If the problem persists, make no further attempts to start.

Contact an IASD.

• output is continually optimized to promote

maximum battery life.

• charging levels are safe.

NOTE: A warning is displayed on the LCD when the

battery needs service.

Shutting Generator Down While Under Load Or During An Extended Run

Proceed as follows to turn the generator off during an extended run to perform maintenance or conserve fuel:

To turn the generator OFF (while running in AUTO and online):

1. Turn the MLCB (generator disconnect) on the gen-

erator to OFF (OPEN).

2. Allow generator to run approximately 1 minute for proper cooling.

3. Press the OFF button on the controller.

To turn the generator back ON:

1. Put the generator into AUTO and allow to start and

warm-up for a few minutes.

2. Set the MLCB (generator disconnect) on the generator to ON (CLOSED).

The system is now in automatic mode. The connected loads can be engaged.

16 Owner’s Manual for 60 Hz EcoGen™ Generators

Section 4: Maintenance

(000182)

WARNING

002389

Maintenance

Regular maintenance will improve performance and extend engine/equipment life. Generac Power Systems, Inc. recommends that all maintenance work be performed by an Independent Authorized Service Dealer (IASD). Regular maintenance, replacement, or repair of the emissions control devices and systems may be performed by any repair shop or person of the owner’s choosing. To obtain emissions control warranty service free of charge, the work must be performed by an IASD. See the emissions warranty.

Preparing for Maintenance

Before performing any maintenance, proceed as follows to prevent the generator from accidental startup:

1. Open lid, turn the generator off and allow the engine to cool. Verify that the unit is OFF.

Performing Scheduled Maintenance

It is important to perform maintenance as specified in the

Service Schedule for proper generator operation. Check

the engine oil level, change the oil filter, and adjust the valve lash after the first 25 hours of operation.

Emissions-critical maintenance must be performed as scheduled in order for the emissions warranty to be valid. Emissions-critical maintenance consists of servicing the air filter and spark plugs in accordance with the Service

Schedule.

The controller will prompt for Schedule A or Schedule B maintenance to be performed. Schedule A maintenance consists of the oil, oil filter, and battery check. Schedule B maintenance includes the oil, oil filter, battery check, air cleaner, spark plug(s), and valve clearance.

Since most maintenance alerts will occur at the same time (most have two year intervals), only one will appear on the control panel display at a time. Once the first alert is cleared, the next active alert will be displayed.

NOTE: Allow the AVR to cool down before removing the

7.5 amp fuse to prevent damage to the AVR. The cool down may take up to 80 minutes.

2. With the generator shut down, remove the front panel.

3. Remove the 7.5 amp fuse from the control panel.

4. Remove the intake side panel. (See Intake Side

Panel Removal.)

5. See Figure 4-1. Disconnect the white battery charger cable.

Figure 4-1. Disconnecting Battery Charger Cable

Owner’s Manual for 60 Hz EcoGen™ Generators 23

Maintenance

Service Schedule

Service Weekly

Check Enclosure Louvers for Dirt and Debris

Check AVR and Engine Filter

Check Lines and Connections for Fuel or Oil Leaks

Check Engine Oil Level

Check Spark Plugs

Check Battery Condition

Replace AVR Filter*

Replace Engine Oil Filter and Oil in Oil Tank**

Replace Engine Air Filter

Replace Spark Plugs

Adjust Valve Clearance***

Replace Rotor Brushes****

Contact the nearest IASD for assistance if necessary. * Replace AVR filter more frequently if operating in dusty conditions. ** Check the engine oil level and change the oil filter *** Check/adjust valve clearance after the first 25 hours of operation. **** Should be performed only by an Independent Authorized Service Dealer.



Every Three

Months

   

Every

Yea r

Schedule A

Every

Two Years

or 500 Hours

Schedule B

Every

Four Years

or 1000 Hours



    



NOTE: Contact an IASD or visit www.generac.com for additional information on replacement parts.

Maintenance Log

Battery inspection and charge check

Dates Performed:

Oil, oil filter, air filter, and spark plug replacement

Dates Performed:

Valve Adjustment

Dates Performed:

24 Owner’s Manual for 60 Hz EcoGen™ Generators

Maintenance

(000139)

WARNING

Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury.

(000210)

WARNING

Skin irritation. Avoid prolonged or repeated contact with used motor oil. Used motor oil has been shown to cause skin cancer in laboratory animals. Thoroughly wash exposed areas with soap and water.

(000135)

CAUTION

Engine damage. Verify proper type and quantity of engine oil prior to starting engine. Failure to do so could result in engine damage.

001384

(000135)

CAUTION

Engine damage. Verify proper type and quantity of engine oil prior to starting engine. Failure to do so could result in engine damage.

Checking Engine Oil Level

Proceed as follows to check the engine oil level:

1. Turn the main line circuit breaker (MLCB) (generator disconnect) on the generator to OFF (OPEN).

2. Disengage the connected loads from the generator.

3. Turn the generator off.

4. Press the control panel OFF button. Wait five

minutes.

2. Allow the generator to start and warm up for a few minutes.

3. Set the generator disconnect on the generator to ON (CLOSED).

4. The system is now operating in automatic mode. The connected loads can now be engaged.

Engine Oil Requirements

To maintain the product warranty, the engine oil should be serviced in accordance with the recommendations of this manual. For your convenience, Generac Maintenance Kits are available that include engine oil, oil filter, air filter, spark plug(s), a shop towel, and a funnel. These kits can be obtained from an IASD.

All Generac oil kits meet minimum American Petroleum Institute (API) Service Class SJ, SL, or better. Do not use special additives.

Required Oil—

Synthetic SAE 5W-30 for all temperature ranges.

Figure 4-2. Dipstick Location

5. See Figure 4-2. Remove the dipstick (A) and wipe it dry with a clean cloth.

6. Completely insert the dipstick and again remove it.

7. Observe the oil level. The level should be at the

“FULL” mark on the dipstick.

8. If necessary, remove the oil fill cap and add oil to the engine until the level reaches the “FULL” mark and reinsert the dipstick and fill cap.

To restart the generator:

1. Press the control panel AUTO button.

Owner’s Manual for 60 Hz EcoGen™ Generators 25

Maintenance

001385

F G

001386

001425

Changing the Oil and Oil Filter

Figure 4-3. Exploded View – EcoGen Oil System Drain Pump Kit

An Oil System Drain Pump Kit (P/N 0K3717) has been shipped with this unit. Refer to the instructions included with that kit for assembly and use of the Oil System Drain Pump. If the Oil System Drain Pump has become lost, or is unavailable, use a suitable suction pump to perform the following oil change procedure.

EcoGen Oil System Drain Pump Kit Parts List

(Kit Part No. 0K3717)

A ¾ in. Spring Clamp**

B ½ in. Rubber Hose**

C ½ in. Barb Hose Fitting with ¾ in. Hose Thread**

D Drill Pump

E ¼ in. Barb Hose Fitting w/¾ in. Hose Thread*

F ½ in. Spring Clamp*

G ¼ in. Rubber Hose*

* Parts 1, 2, and 6 come assembled from the supplier. ** Parts 3, 4, and 7 come assembled from the supplier.

EcoGen Oil System Drain Pump Assembly

1. See Figure 4-4. Install the ¼ in. Hose Assembly

onto the inlet side of the Drill Pump. Twist the fitting clockwise until it is snug. Do not over-tighten.

Figure 4-4. Pump Assembly Step 1

2. See Figure 4-5. Install the ½ in. Hose Assembly onto the outlet side of the Drill Pump. Twist the fitting clockwise until it is snug. Do not over-tighten.

Figure 4-5. Pump Assembly Step 2

26 Owner’s Manual for 60 Hz EcoGen™ Generators

EcoGen Oil Change Procedure

(000210)

WARNING

Skin irritation. Avoid prolonged or repeated contact with used motor oil. Used motor oil has been shown to cause skin cancer in laboratory animals. Thoroughly wash exposed areas with soap and water.

001387

001426

001389

001390

1. Place the MLCB to the OFF position.

2. Press the Control Panel MANUAL button to

operate the unit.

3. Verify the engine is at operating temperature by operating the unit for a minimum of 20 minutes.

4. Press the Control Panel OFF button to shut down the engine.

5. Allow the oil to settle for 10 minutes.

NOTE: Allowing the engine to run at operating

temperature increases engine oil viscosity so that it can be easily drawn out of the system. Allowing the oil to settle ensures that the oil has thoroughly drained to the tank and that the equipment is cool enough to handle during the procedure. Always follow proper safety precautions when working with this equipment.

Maintenance

Figure 4-7. Attaching Drill Pump

10. See Figure 4-8. Insert the ¼ in. hose free end into the unit’s oil tank.

6. See Figure 4-6. Remove the used oil filter (A) by turning it counterclockwise. A towel or small container may be used to catch any residual oil when removing the filter.

Figure 4-6. Oil Filter and Dipstick

7. Remove the oil dipstick (B) from the tank.

8. Set a drill to spin in the clockwise direction.

9. See Figure 4-7. Attach the drill to the drive shaft of

the Drill Pump.

Figure 4-8. Drain Hose In Oil Tank

11. See Figure 4-9. Insert the ½ in. hose free end into a suitable oil catch container. Make sure there are no kinks or obstructions in either hose.

Figure 4-9. Draining Into Oil Catch Container

12. Spin the pump on the high speed setting of the drill.

NOTE: It may take up to 2 minutes to prime the pump.

Owner’s Manual for 60 Hz EcoGen™ Generators 27

13. After oil begins pumping, draw out as much oil as possible. A total of 2.5–3.5 quarts (2.37– 3.31 L) of oil should be removed from the system.

14. Remove the ¼ in. hose from the tank and drain remaining oil from the drill pump and hoses.

15. Apply a light coating of new oil to the gasket of the new oil filter.

Maintenance

001221

001222

(000223)

WARNING

Electric shock. AVR maintains electrical charge after generator shutdown. Wait five minutes before AVR removal. Failure to do so could result in death or serious injury.

16. Screw the new oil filter on by hand until the filter gasket contacts the oil filter adapter. Tighten the new oil filter ¾ to one full turn more.

17. Refill the oil tank with the proper recommended oil. Do not fill above the full mark on the dipstick.

18. Start the engine, run for one minute and check for leaks.

19. Stop the engine for a minimum of 10 minutes.

20. Recheck the oil level and add oil if necessary.

21. Place the MLCB to the ON position.

22. Place the unit back into service by pressing the

control panel AUTO button.

Dispose of used engine oil and oil filter at a proper collection center.

Replacing the Engine Air Filter

1. With the generator shut down, lift the lid and

remove the front panel.

2. See Figure 4-10. Remove the cover clip (A) and air cleaner cover (B).

6. Install the air cleaner cover and cover clip.

Replacing the AVR Filter

001219

Figure 4-12. Removing the AVR Filter Screw

Figure 4-10. Removing the Air Cleaner Cover

3. See Figure 4-11. Pull out the old air filter (C) and discard.

Figure 4-13. Replacing the AVR Filter

1. See Figure 4-12. Remove screw to release AVR filter housing from back panel.

2. Remove AVR filter housing.

3. See Figure 4-13. Grasp rubber lifting strap and

remove filter from filter housing.

Figure 4-11. Removing the Air Filter

4. Thoroughly clean the air cleaner enclosure of any dust or debris.

5. Install a new air filter.

28 Owner’s Manual for 60 Hz EcoGen™ Generators

4. Install new filter (See Replacement Parts), so that edge is positioned inboard of two tabs on filter housing.

5. Install AVR filter housing so the bottom drops into the slots, ensuring that the rubber boot is completely around the fan opening. Install screw to fasten AVR filter housing to back panel and torque to 50–96 in-lbs (6–11 Nm).

001220

Maintenance

(000140)

Electrical shock. Do not disconnect spark plug wires with engine running. Doing so could result in death or serious injury.

WARNING

(000222a)

WARNING

Moving Parts. Avoid AVR fan housing for 80 minutes after generator shutdown. Fan operates even if fuse is removed. Rotating fan blades could result in death or serious injury.

(000223)

WARNING

Electric shock. AVR maintains electrical charge after generator shutdown. Wait five minutes before AVR removal. Failure to do so could result in death or serious injury.

000211

(000130)

WARNING

Accidental Start-up. Disconnect the negative battery cable, then the positive battery cable when working on unit. Failure to do so could result in death or serious injury.

(000223)

WARNING

Electric shock. AVR maintains electrical charge after generator shutdown. Wait five minutes before AVR removal. Failure to do so could result in death or serious injury.

001404

Maintaining the Spark Plugs

Check and replace the spark plugs as necessary.

1. With the generator shut down, lift the lid and remove the front panel.

2. See “A” in Figure 4-12. Remove screw to release AVR filter housing from back panel.

3. Clean the area around the base of the spark plugs to keep dirt and debris out of the engine.

Remove spark plug cables from spark plug terminals

5. Remove the spark plugs and check the condition. Install new plugs if the old spark plugs are worn or if reuse is questionable.

6. Clean the spark plugs by scraping or washing with a wire brush and commercial solvent. Do not blast the spark plugs to clean.

7. See Figure 4-14. Check spark plug gap using a wire feeler gauge. Replace the spark plug if the gap is not within specification as provided in Section 2 — Specifications.

10. Install AVR filter housing.

11. Install front panel and lower the generator lid.

Valve Clearance Adjustment

Check the valve clearance after the first 25 hours of operation, then as per recommended service interval (See Service Schedule). Adjust if necessary.

Important: Please contact an Independent Authorized Service Dealer for service assistance. Proper valve clearance is essential for prolonging the life of the engine.

Check Valve Clearance

1. Verify that engine is at ambient air temperature.

NOTE: Allow the AVR to complete its cool down before

disconnecting power, which is indicated by the green light turning off.

2. See Figure 4-12. Remove screw to release AVR filter housing from back panel. Remove AVR filter housing.

3. See Figure 4-15. Depress external latch to disconnect 4-pin connector (A) from AVR.

4. See Figure 4-16. Remove three screws (B) to release AVR fan from AVR.

Figure 4-14. Checking Spark Plug Gap

8. Install the spark plugs and torque to 18.4 ft-lbs (25 Nm).

9. Attach spark plug cables to spark plug terminals.

Owner’s Manual for 60 Hz EcoGen™ Generators 29

Figure 4-15. Remove AVR Fan Connector

Maintenance

001414

002380

Figure 4-16. Remove AVR Fan Screws

5. Remove spark plug cables from spark plug terminals.

6. Remove spark plugs.

7. Make sure the piston is at top dead center (TDC) of

its compression stroke (both valves closed). To move the piston to TDC, remove the intake screen at the front of the engine to access the flywheel nut. Use a large socket and socket wrench to rotate the flywheel nut clockwise, which will rotate the crankshaft. Watch the piston through the spark plug hole. The piston should move up and down. The piston is at TDC when it is at its highest point of travel.

Adjust Valve Clearance

See Figure 4-17. Proceed as follows to adjust the valve clearance:

NOTE: Allow engine to cool before adjusting valve clearance.

1. Remove spark plug wire(s) and position wire(s) away from plugs.

2. Remove spark plug(s).

3. Remove the four screws attaching the valve cover.

Remove and discard gasket.

4. Make sure the piston is at top dead center (TDC) of its compression stroke (both valves closed).

5. Loosen the rocker jam nut (C) using a 13 mm wrench.

Figure 4-17. Valve Clearance Adjustment

6. Turn the pivot ball stud (D) using a 10 mm Allen wrench while checking clearance between the rocker arm (E) and the valve stem (F) with a feeler gauge. Adjust clearance as per Specifications.

NOTE: Hold the rocker arm jam nut in place as the pivot ball stud is turned.

7. When valve clearance is correct, hold the pivot ball stud (B) in place with a wrench and tighten the rocker arm jam nut. Tighten the jam nut to 174 inlbs (19.68 Nm).

8. After tightening the jam nut, recheck valve clearance to verify it did not change.

9. Install new valve cover gasket.

10. Install the valve cover. Tighten fasteners in a cross

pattern, torquing to 60 in-lbs (6.8 Nm).

NOTE: Start all four screws before tightening, or it will not be possible to get all the screws in place. Verify the valve cover gasket is in place.

11. Install spark plugs and torque to 18 ft-lbs (25 Nm).

12. Attach the spark plug wire to the spark plug.

13. Connect the AVR fan to the AVR using the three

screws.

14. Connect the 4-pin connector to the AVR.

15. Install AVR filter housing so the bottom drops into

the slots, ensuring that the rubber boot is completely around the fan opening. Install screw to fasten AVR filter housing to back panel and torque to 50–96 in-lbs (6–11 Nm)

16. Repeat the process for the other cylinder if necessary.

30 Owner’s Manual for 60 Hz EcoGen™ Generators

Battery Maintenance

–

(000162)

WARNING

Explosion. Do not dispose of batteries in a fire.

Batteries are explosive. Electrolyte solution can cause burns and blindness. If electrolyte contacts skin or eyes, flush with water and seek immediate medical attention.

(000137a)

WARNING

(000164)

WARNING

Electrical shock. Disconnect battery ground terminal before working on battery or battery wires. Failure to do so could result in death or serious injury.

(000138a)

WARNING

(000228)

The battery should be regularly inspected per the

Service Schedule. Contact an IASD for assistance if

necessary.

Proceed as follows to inspect the battery:

1. Press the OFF button to shut down the generator, then lift the lid and remove the front panel.

2. Remove the 7.5 amp fuse from the control panel.

3. Remove the intake side panel. (See Intake Side

Panel Removal.)

4. See Figure 4-1. Disconnect the white battery charger cable.

NOTE: Allow the AVR to cool and the fan to stop before removing the battery. Removing the battery before the AVR has stopped can damage the AVR and injure the operator.

5. See Figure 4-18. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary.

Maintenance

001832

Figure 4-18. Battery Cables

6. (Unsealed batteries only): Completely disconnect the battery. Check the battery fluid level and, if necessary, fill with distilled water only. DO NOT use tap water. Also, have an IASD or a qualified service technician check the state of charge and condition.

7. When inspection is complete, reconnect the battery cables, the battery charger cable, reinstall the intake side panel, and reinstall the 7.5 amp fuse.

Place the controller in AUTO mode.

Install the front panel and close the generator lid.

• DO NOT smoke when near the battery.

• DO NOT cause flame or spark in the battery area.

• Discharge static electricity from the body before

touching the battery by first touching a grounded metal surface.

Cleaning the Sediment Trap

The sediment trap removes contaminants (moisture and fine particles) from gaseous fuels before they enter the fuel regulator. Accumulated moisture and particles must be emptied from the sediment trap per local codes and guidelines.

Proceed as follows to clean the sediment trap:

1. Remove the intake side panel (see Intake Side

Panel Removal).

2. Turn the generator fuel supply off.

See

Figure 4-19

. Unscrew and remove the cap (A).

Owner’s Manual for 60 Hz EcoGen™ Generators 31

Maintenance

001821

WARNING

Explosion. Batteries emit explosive gases. Always disconnect negative battery cable first to avoid spark. Failure to do so could result in death or serious injury.

(000238)

Figure 4-19. Cleaning the Sediment Trap

4. Use a clean-out tool (not provided) to remove accumulated moisture and particles from the cap and body (B).

5. Wipe the inside of each component with a clean, dry, lint-free cloth.

6. Seal the threads of the cap with appropriate sealing compound. Install the cap and handtighten.

7. Tighten the cap with an appropriately sized pipe wrench. DO NOT overtighten.

8. Turn the generator fuel supply on. Check for leaks by spraying all connection points with a noncorrosive gas leak detection fluid. The solution should not be blown away or form bubbles.

9. Install the intake side panel.

Remove From, and Return To Service Procedure

Remove From Service

If the generator will be out of service longer than 90 days, proceed as follows to prepare the generator for storage:

1. Start the engine and let it warm up.

2. Close the fuel shutoff valve in the fuel supply line

and allow the engine to stop.

3. Once the engine has stopped, set the generator MLCB (generator disconnect) to OFF (OPEN).

4. Disengage the connected loads to the generator.

5. See Figure 4-1. Remove battery charger AC input

T1/Neutral cable (has white sleeve) at controller.

NOTE: Allow the AVR to cool and the fan to stop before removing the battery. Removing the battery before the AVR has stopped can damage the AVR and injure the operator.

6. Remove the 7.5 amp fuse from the generator’s control panel.

7. Disconnect the battery cables. Remove the negative cable first.

Attention After Submersion

DO NOT start or operate the generator if it has been submerged in water. Have an IASD thoroughly clean, dry, and inspect the generator following any submersion in water. If the structure (home) has been flooded, it should be inspected by a certified electrician to verify there won’t be any electrical problems during generator operation or when connected loads are engaged.

Corrosion Protection

Regular scheduled maintenance should be conducted to perform a visual inspection of the unit for corrosion. Inspect all metal components of the generator, including the base frame, brackets, alternator can, the entire fuel system (inside and outside of the generator), and fastener locations. If there is corrosion found on generator components (e.g. regulator, engine/alternator mounts, fuel plenum, etc.), replace parts as necessary.

Periodically wash and wax the enclosure using automotive type products. Do not spray the unit with a hose or power washer. Use warm, soapy water and a soft cloth. Frequent washing is recommended in salt water/ coastal areas. Spray engine linkages with a light oil such as WD-40.

32 Owner’s Manual for 60 Hz EcoGen™ Generators

8. Drain the oil completely while the engine is still warm, and then refill the oil tank with oil.

9. Attach a tag to the engine indicating the viscosity and classification of the new oil in the oil tank.

10. Remove the spark plug(s) and spray a fogging agent into the spark plug(s) threaded openings. Reinstall and tighten the spark plug(s) to specification.

11. Remove the battery and store it in a cool, dry room on a wooden board.

12. Clean and wipe down the entire generator.

Return to Service

Proceed as follows to return the unit to service after storage:

1. Verify the connected loads are disengaged.

2. Check the tag on the engine for oil viscosity and

classification. Drain and refill with proper oil, if necessary.

3. Check the state of the battery. (Unsealed batteries only) Fill all cells of unsealed batteries to the proper level with distilled water. DO NOT use tap water. Recharge the battery to 100% state of

charge. Replace the battery if it will not maintain a charge.

4. Clean and wipe down the entire generator.

5. Verify that the 7.5 amp fuse is removed from the

generator control panel.

6. Reconnect the battery. Observe battery polarity. Damage may occur if the battery is connected incorrectly. Install positive cable first.

7. Reconnect the battery charger AC input T1/Neutral cable (white sleeve) at controller.

8. Open the fuel shutoff valve.

9. Insert the 7.5 amp fuse into the generator control

panel.

10. Press the MANUAL button to start the unit. Allow the unit to warm up for a few minutes.

11. Complete the Installation Wizard information.

12. Press the control panel OFF button to stop the unit.

13. Engage the connected loads to the generator.

14. Set the control panel to AUTO.

The generator is ready for service.

Maintenance

NOTE: The current date and time must be reset when a battery is dead or has been disconnected.

Owner’s Manual for 60 Hz EcoGen™ Generators 33

Maintenance

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34 Owner’s Manual for 60 Hz EcoGen™ Generators

Troubleshooting / Quick Reference Guide

Section 5: Troubleshooting / Quick Reference Guide

Generator Troubleshooting

Problem Cause Correction

Engine will not crank.

Engine cranks but will not start.

Engine starts hard and runs rough.

Generator is set to OFF, but the engine continues to run.

1. Blown fuse.

2. Loose, corroded, or defective battery cables.

3. Defective starter contact.

4. Defective starter motor.

5. Discharged battery.

1. No fuel.

2. Defective fuel solenoid (FS).

3. Open Wire 14 from controller.

4. Defective spark plug(s).

5. Valve clearance out of adjustment.

6. Fuel pressure too high

1. Air cleaner plugged or damaged.

2. Defective spark plug(s).

3. Incorrect fuel pressure.

4. Fuel selector in wrong position.

5. Valve(s) out of adjustment.

6. Internal engine issue.

1. Controller wired incorrectly.

2. Defective control board.

1. Correct short circuit condition by replacing 7.5 amp fuse in generator control panel. Contact an Independent Authorized Service Dealer (IASD) if fuse continues to blow.

2. Tighten, clean, or replace as necessary.*

3. *See #2.

4. *See #2.

5. Charge or replace battery.

1. Replenish fuel / turn on fuel valve.

2. *

3. *

4. Clean; check gap; replace plug(s) if necessary.

5. Reset valve clearance.

6. Verify proper fuel pressure

1. Check and clean air cleaner.

2. Clean; check gap; replace plug(s) as needed.

3. Confirm fuel pressure to regulator is 10–12 in water column (19–22 mm Hg) for LP, and 3.5–7.0 in water column (9–13 mm Hg) for natural gas.

4. Turn fuel conversion valve to correct position.

5. Adjust valve clearance.

6. *

1. *

2. *

No AC output from generator.

1. Main line circuit breaker (MLCB) (generator disconnect) is OFF (OPEN).

2. Generator internal failure.

3. Engine may be warming up. Refer to

Smart Start

No transfer to generator power after startup.

Unit consumes large amounts of oil.

* Contact an IASD for assistance.

1. MLCB (generator disconnect) is OFF (OPEN).

2. Engine may be warming up. Refer to

Smart Start

1. Excessive engine oil.

2. Defective engine breather.

3. Improper type or viscosity of oil.

4. Damaged gasket, seal, or hose.

5. Restricted air filter.

1. Reset generator disconnect to ON (CLOSED).

2. *

Cold

3. Check the controller screen to verify status.

1. Reset generator disconnect to ON (CLOSED).

2. Check the controller screen to verify status.

1. Adjust oil to proper level.

2. *

Engine Oil Requirements.

3. See

4. Check for oil leaks.

5. Replace air filter.

Owner’s Manual for 60 Hz EcoGen™ Generators 35

Troubleshooting / Quick Reference Guide

Quick Reference Guide

To clear an active alarm, press the OFF button, the ENTER button, and then press AUTO. If the alarm reoccurs, contact an IASD.

Active Alarm LED Problem Things to Check Solution

NONE

HIGH

TEMPERATURE

OVERLOAD

REMOVE LOAD

RPM SENSE LOSS RED

NOT ACTIVATED NONE

NONE GREEN

LOW OIL

PRESSURE

RPM SENSE LOSS RED

FLASHING

GREEN

RED

Unit running in AUTO but no power at L1 and L2.

Unit shuts down during operation.

Unit was running and shut down, attempts to restart.

Unit will not start in AUTO with remote start signal.

Check MLCB. Check MLCB. If it is ON, contact an IASD.

Check the LEDs / screen for alarms.

Check if screen says unit not activated.

Check screen for start delay countdown.

Check the LEDs / screen for alarms.

Check ventilation around the generator, intake, exhaust, and rear of generator. If no obstructions are present, contact an IASD.

Clear alarm and remove household loads from the generator. Put in AUTO and restart.

Clear alarm and remove household loads from the generator. Put into AUTO and restart. If generator does not start, contact an IASD.

Refer to “Activation” in installation manual.

If the startup delay is greater than expected, contact an IASD to adjust.

Check oil level and add oil as needed. If oil level is correct, contact an IASD.

Clear alarm. Using the control panel, check the battery by navigating to the BATTERY MENU option from the MAIN MENU. If battery condition displays GOOD, contact an IASD. If control panel displays CHECK BATTERY, replace the battery.

Unit will not start in

OVERCRANK RED

LOW VOLTS

REMOVE LOAD

FUSE PROBLEM RED

OVERSPEED RED

UNDERVOLTAGE RED

36 Owner’s Manual for 60 Hz EcoGen™ Generators

RED

AUTO with remote start signal.

Unit will not start in AUTO with remote start signal.

Check the LEDs / screen for alarms.

Check fuel line shutoff valve is ON. Clear alarm. Start the unit in MANUAL. If it does not start, or starts and runs rough, contact an IASD.

Clear alarm and remove household loads from the generator. Put in AUTO and restart.

Check the 7.5 amp fuse. If it is blown, replace it with an ATO 7.5 amp fuse. If the fuse is intact, contact an IASD.

Contact an IASD.

Troubleshooting / Quick Reference Guide

Active Alarm LED Problem Things to Check Solution

UNDERSPEED RED

STEPPER

OVERCURRENT

MISWIRE RED

OVERVOLTAGE RED

LOW BATTERY YELLOW

BATTERY

PROBLEM

CHARGER

WARNING

RED

YELLOW

Unit will not start in AUTO with remote start signal.

Yellow LED illuminated in any state.

Check the LEDs / screen for alarms.

Check the screen for additional information.

Contact an IASD.

SERVICE A YELLOW

SERVICE B YELLOW

INSPECT BATTERY YELLOW

Yellow LED illuminated in any state.

Check the screen for additional information.

Perform SERVICE A maintenance. Press ENTER to clear.

Perform SERVICE B maintenance. Press ENTER to clear.

Inspect battery. Press ENTER to clear.

Owner’s Manual for 60 Hz EcoGen™ Generators 37

Troubleshooting / Quick Reference Guide

AVR Troubleshooting

Table 5-1. AVR Troubleshooting

Ecode/Active

LED Problem Things to

Alarm

1048 VSCF Overload RED Unit shuts down

during operation.

1049 VSCF Overload RED Unit shuts down

during operation.

1051 VSCF High Battery

1052 VSCF DC Overvoltage

1053 VSCF Gate Fault

1054 VSCF IGBT Overtemp.

1055 VSCF Phase Error

1056 VSCF Undervoltage

YELLOW Yellow LED

illuminated in any state.

RED Unit shuts down

during operation.

RED Unit shuts down

during operation or starting.

RED Unit shuts down

during operation or starting.

RED Unit shuts down

during starting.

RED Unit shuts down

during operation or starting.

Check

Check the LEDs/Screen for alarms.

Possible Causes/Solution

Alternator, AVR or wiring is damaged. Contact servicing dealer.

Generator output is shorted or severely overloaded. Identify and clear the overload, and then restart.

Voltage supply to the AVR is high. If an external battery charger is in use, contact installing dealer to correct installation. If an external battery charger is NOT in use, contact servicing dealer.

Probable causes are:

1) The generator was temporarily overloaded.

2) The output was temporarily shorted. Try to restart the unit.

AVR is damaged. Contact servicing dealer.

Probable causes are:

1) Replace AVR filter. Inspect fan.

2) Intake or exhaust air path is blocked. Check intake and exhaust.

3) The BIG fan is not running (Note: only runs when the engine is running). KEEP FINGERS AWAY FROM FAN

HOUSING- PERSONAL INJURY CAN OCCUR IF FAN IS RUNNING. Contact servicing dealer.

4) Air leak in AVR enclosure. Contact servicing dealer.

5) Engine running too hot. Inspect air intake and exhaust.

6) Ambient temperature has risen above 60º F. Derate the generator output per specifications.

An incorrect voltage and frequency has been detected during starting. Probable causes are:

1) Alternator damage. Contact servicing dealer.

2) Generator has started into a severe load. Manually operate generator breaker and try to restart unit. If problem persists, remove load and attempt to restart unit again.

3) The engine may not be reaching its prescribed speed. Proceed as follows:

• Verify stepper motor is moving and linkage is free.

• Verify stepper motor is plugged in.

• Verify gas pressure is within specified limits.

The generator output voltage is too low. Probable causes are:

1) The load is too large. Remove load and attempt to restart unit.

2) Alternator or AVR damage. Contact servicing dealer.

38 Owner’s Manual for 60 Hz EcoGen™ Generators

Troubleshooting / Quick Reference Guide

Table 5-1. AVR Troubleshooting

Ecode/Active

LED Problem Things to

Alarm

1057 VSCF Overvoltage

1058 VSCF DC Undervoltage

1059 VSCF Field Loss

1061 VSCF Field Loss

1060 Big Fan Failure RED Unit shuts down

1065 Overfrequency RED Unit shuts down

1066 VSCF Speed mismatch

1070 Small fan failure

RED Unit shuts down

during operation or starting.

RED Unit shuts down

during operation or starting.

RED Unit shuts down

during starting.

RED Unit shuts down

during operation.

RED Unit shuts down

during Operation or starting.

YELLOW “Small fan failure”

is displayed. If unit was running in AUTO, it will continue to run for 80 minutes to cool electronics without fan.

Check

Check the LEDs/Screen for alarms.

Possible Causes/Solution

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. If problem persists, remove load and attempt to restart unit again.

The DPE winding supplies this voltage.

1) Alternator damage. Contact servicing dealer.

Unit detects no output voltage while starting.

1) Alternator damage. Contact servicing dealer.

Unit detects loss of output voltage while running.

1) Alternator damage. Contact servicing dealer.

This alarm occurs when the AVR electronics temperature exceeds 70 C. Possible causes are:

1) AVR filter faulty. Replace AVR filter.

2) Intake or exhaust air path is blocked. Check intake and exhaust.

3) The BIG fan is not running (Note: only runs when the engine is running). KEEP FINGERS AWAY FROM FAN

HOUSING- PERSONAL INJURY CAN OCCUR IF FAN IS RUNNING. Contact servicing dealer.

4) Air leak in AVR enclosure. Contact servicing dealer.

5) Engine running too hot. Inspect air intake and exhaust.

6) Ambient temperature has risen above 60º F. Derate the generator output per specifications.

If message is displayed when generator is stopped, also check SMALL fan. Small fan RUNS for 80 minutes after generator is stopped and keeps electronics cool during heat soak.

Probable causes are:

1) Overload. Remove load and attempt to restart unit.

2) RPM sensor has failed. Contact servicing dealer.

3) Stepper motor problem. Contact servicing dealer.

1) Fuel problem (pressure loss). Check fuel supply and attempt to restart unit.

2) Large overload. Remove load and attempt to restart unit.

3) Throttle or engine problem. Contact servicing dealer.

Small fan current incorrect. Probable causes are:

1) Fan wiring or mechanical problem. Contact servicing dealer.

2) Air path is blocked. Check AVR filter. KEEP FINGERS AWAY FROM FAN HOUSING-

PERSONAL INJURY CAN OCCUR IF FAN IS RUNNING.

Owner’s Manual for 60 Hz EcoGen™ Generators 39

Troubleshooting / Quick Reference Guide

AVR Diagnostics

Table 5-2. AVR Diagnostics

Symptom Possible Causes

Generator stalls when large load is supplied.

Output voltage is low/high. Voltage calibration incorrect. Contact servicing dealer.

Generator does not pull full power. Current calibration incorrect. Contact servicing dealer.

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.

40 Owner’s Manual for 60 Hz EcoGen™ Generators

Part No. 0L6633 Rev. A 09/13/16 ©2016 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.com

Generac Power Systems 15 kW EcoGen Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Section 1: Safety Rules & General Information

Introduction

Read This Manual Thoroughly

Safety Alerts

How to Obtain Service

Safety Rules

General Hazards

Electrical Hazards

Exhaust Hazards

Fire Hazards

Explosion Hazards

Section 2: General Information

EcoGen Operating Principle

Benefits

How It Works

Normal Running

Small Load Changes

Large Load (Not Overload)

Automatic Voltage Regulator (AVR) Cooling Fans

Startup

The Generator

Specifications

Generator

Engine

Protection Systems

Emission Information

Fuel Requirements

Battery Requirements

Battery Charger

Engine Oil Requirements

Activating the Generator

Replacement Parts

Accessories

Section 3: Operation

Site Prep Verification

Generator Enclosure

Opening the Lid

Intake Side Panel Removal

Main Line Circuit Breaker (Generator Disconnect)

LED Indicator Lights

Control Panel Interface

Using the AUTO/OFF/MANUAL Interface

Interface Menu Displays

USB Port for Firmware Updates

The LCD Panel

Menu System Navigation

Battery Charger

Automatic Sequence of Operation

Cranking

Cold Smart Start

Shutting Generator Down While Under Load Or During An Extended Run

To turn the generator OFF (while running in AUTO and online):

To turn the generator back ON:

Section 4: Maintenance

Maintenance

Preparing for Maintenance

Performing Scheduled Maintenance

Maintenance Log

Checking Engine Oil Level

Engine Oil Requirements

Changing the Oil and Oil Filter

EcoGen Oil System Drain Pump Kit Parts List

EcoGen Oil System Drain Pump Assembly

EcoGen Oil Change Procedure

Replacing the Engine Air Filter

Replacing the AVR Filter

Maintaining the Spark Plugs

Valve Clearance Adjustment

Check Valve Clearance

Adjust Valve Clearance

Battery Maintenance

Cleaning the Sediment Trap

Remove From, and Return To Service Procedure

Remove From Service

Attention After Submersion