Installation Guidelines
For
Automatic S tandby Generator
15 kW EcoGen™
NOT INTENDED FOR USE IN CRITICAL
*
*
*
This manual should remain with the unit.
This manual must be used in conjunction
with the appropriate owner’s manual.
To locate in Spanish, go to http://www.generac.com/service‐support/product‐support‐lookup
To locate in French, go to http://www.generac.com/service‐support/product‐support‐lookup
LIFE SUPPORT APPLICATIONS.
ONLY QUALIFIED ELECTRICIANS OR
CONTRACTORS SHOULD ATTEMPT
INSTALLATION!
DEADLY EXHAUST FUMES! OUTDOOR
INSTALLATION ONLY!
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.
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.
ii Installation Guidelines for Air-Cooled Generators
Table of Contents
Section 1
1.1 Introduction .......................................................................................................................... 1
1.1.1 Read This Manual Thoroughly ......................................................................................................1
1.1.2 How to Obtain Service ..................................................................................................................2
1.2 Safety Rules ..........................................................................................................................2
1.2.1 General Hazards ...........................................................................................................................3
1.2.2 Electrical Hazards .........................................................................................................................3
1.2.3 Fire Hazards .................................................................................................................................3
1.2.4 Explosion Hazards ........................................................................................................................4
1.3 General Rules .......................................................................................................................4
1.3.1 Before You Begin ..........................................................................................................................4
1.3.2 Standards Index ............................................................................................................................4
Section 2 Unpacking and Inspection
2.1 General ..................................................................................................................................7
2.2 Required Tools .....................................................................................................................7
2.3 Unpacking .............................................................................................................................8
2.4 Parts Shipped Loose .........................................................................................................11
Section 3 Site Selection and Preparation
3.1 Site Selection ......................................................................................................................13
3.1.1 Installation Guidelines .................................................................................................................14
3.2 Site Preparation ..................................................................................................................15
3.2.1 Material Sufficient for Level Installation ......................................................................................16
Section 4 Generator Placement
4.1 Generator ............................................................................................................................17
4.2 Fascia Skirt Installation (If Applicable) ............................................................................18
Section 5 Fuel Conversion/Gas Connections
5.1 Fuel Conversion .................................................................................................................19
5.2 Fuel Requirements and Recommendations ....................................................................19
5.3 Fuel Consumption ..............................................................................................................20
5.4 Fuel Line Sizing ..................................................................................................................20
5.4.1 Natural Gas Pipe Sizing ..............................................................................................................21
5.4.2 LP Vapor Pipe Sizing ..................................................................................................................21
5.4.3 Gas Installation Summary ...........................................................................................................22
5.5 Installing and Connecting Gas Lines ...............................................................................22
Installation Guidelines for Air-Cooled Generators iii
Table of Contents
Section 6 Electrical Connections
6.1 Generator Connections ......................................................................................................27
6.2 Control Wiring .....................................................................................................................27
6.3 Main AC Wiring ...................................................................................................................29
6.4 Automatic Voltage Regulator (AVR) Cooling Fans .........................................................29
6.5 Battery Requirements ........................................................................................................30
6.6 Battery Installation .............................................................................................................30
Section 7 Operation
7.1 Control Pad .........................................................................................................................31
7.2 Auto/Manual/Off ..................................................................................................................32
7.3 Menu Navigation .................................................................................................................33
7.4 Change Time and Date .......................................................................................................33
7.5 Programmable Timers ........................................................................................................33
7.5.1 Dealer Programmable ................................................................................................................33
7.6 USB Port for Firmware Updates ........................................................................................33
7.7 Before Initial Start-Up .........................................................................................................34
7.7.1 Installation Wizard ......................................................................................................................34
7.7.2 Before Starting ............................................................................................................................36
7.8 Electrical Checks ................................................................................................................36
7.9 Generator Tests Under Load .............................................................................................36
7.10 Checking Automatic Operation .......................................................................................37
7.11 Installation Summary .......................................................................................................37
Section 8 Troubleshooting
8.1 Engine Troubleshooting ....................................................................................................39
8.2 Generator Troubleshooting ...............................................................................................40
8.3 G-Flex™ Troubleshooting .................................................................................................42
Section 9 Accessories
9.1 Descriptions ........................................................................................................................45
Section 10 Installation Diagrams
10.1 Installation Drawing .........................................................................................................47
10.2 Off Grid Mode Application Schematic ............................................................................48
10.3 Oil Make Up System Schematic ......................................................................................49
iv Installation Guidelines for Air-Cooled Generators
Section 1
Safety and General Information
1.1 — Introduction
Thank you for purchasing this compact, high performance, variable speed, air-cooled, engine-driven stationary automatic standby generator set. Every ef fo rt has been made to en sure that the informatio n and instructions in this manual
are both accurate and complete at the time of release. However, the manufacturer reserves the right to change, alter,
or otherwise improve this product at any time without prior notice.
In off-grid applications as a part of an alternative en ergy system, the gen erator st ar t s wh en the inver ter/battery cha rger
detects the battery pack voltage has dropped below a preset level. The generator powers the inverter, and once the
voltage level of the battery 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 gen-
erator can be operated using either natural gas (NG) or vapor withdrawn liquid propane (LP).
NOTE: When properly sized, 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.
1.1.1— Read This Manual Thoroughly
The operator is responsible for proper and safe use of this equipment. The manufacturer strongly recommends that the
operator read and thoroughly understand the instructions and content s of this owner’s manual before attempting to use
the equipment. If any portion of this publication is not understood, contact the nearest Authorized Service Dealer for
starting, operating and servicing procedures.
Throughout this publication and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and
NOTE 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:
Indicates a hazardous situation or action that, if not avoided, will result in death or serious
injury.
Indicates a hazardous situation or action that, if not avoided, could result in death or serious injury.
Indicates a hazardous situation or action that, if not avoided, could result in minor or moderate injury.
NOTE: Notes provide additional information important to a procedure or component.
These safety warnings cannot eliminate the hazards they indicate. Ob servin g safe ty pr ecautio ns and strict compliance
with the special instructions while performing the ac tion or se rvic e ar e es sen tia l to pr ev en tin g ac cide n ts.
Four commonly used safety symbols accompany DANGER, WARNING, and CAUTION boxes and the type of information each indicates:
Installation Guidelines for Air-Cooled Generators 1
This symbol points out important safety information that, if not followed, could
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endanger personnel and/or property.
This symbol represents the potential for an Explosion Hazard.
This symbol represents the potential for a Fire Hazard.
This symbol represents the potential for an Electrical Shock Hazard.
The operator is responsible for proper and safe use of the equipment. The manufacturer strongly recommends that if
the operator is also the owner, to read their Owner’s Manual and thoroughly understand all instructions before using
this equipment. The manufacturer also strongly recommends instructing other user s to properly start and operate the
unit. This prepares them if they need to operate the equipment in an emergency.
1.1.2— How to Obtain Service
When the generator requires servicing or repairs, contact a Dealer for assistance. Service technicians are factorytrained and are capable of handling all service needs. For assistance locating a dealer, call our dealer locater at 800333-1322 or visit us at www.gene rac.com/dealer-locator.
When contacting a Dealer about part s and service, always supply the complete model numbe r and serial number of the
unit as given on its data decal, which is located on the generator. See section “The Generator” for decal location.
Model No. _____________________ Serial No. __________________________
1.2 — Safety Rules
Save These Instructions – The manufacturer suggests that these rules for safe operation be copied
and posted near the unit’s installation site. Safety should be stressed to all operators and potential
operators of this equipment.
Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with
this Installation 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 warnings in this
manual and on tags and decals affixed to the unit are, therefore, n ot all-inclusive. If using a procedure, work method or
operating technique the manufacturer does not specifically recommend, ensure that it is safe for others. Also, make
sure the procedure, work method or operating technique utilized does not render the generator unsafe.
Despite the safe design of this generator, operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to install, operate and maintain this equipment.
Potentially lethal voltages are generated by these machines. Ensure all steps are taken to render the
machine safe before attempting to work on the generator.
Parts of the generator are rotating and/or hot during operation. Exercise care near running generators.
Installation must always comply with applicable codes, standards, laws and regulations.
A running generator gives off carbon monoxide, an odor less, colorless poison gas. Brea thing in carbon
monoxide can cause headaches, fatigue, dizziness, nausea, vomiting, c onfusion, fainting, seizures or
death.
2 Installation Guidelines for Air-Cooled Generators
1.2.1— General Hazards
•
For safety reasons, the manufacturer recommends that this equipment be installed by an independent Sales or
Service Dealer or other competent, qualified electrician or installation technician who is familiar with applicable
codes, standards and regulations. The operator also must comply with all such codes, standards and regulations. Only an Independent Authorized Service Dealer is allowed to perform warranty service on this unit.
• 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 battery-operated carbon monoxide alarm indoors, according to manu facturer’s instructions/recommen-
dations.
• Adequate, unobstructed flow of cooling and ventilating air is critical to correct generator operation. Do not alter
the installation or permit even partial blockage of ventilation provisio ns, as this can seriously affect sa fe operation
of the generator. The generator MUST be installed and operated outdoors only.
• Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any
drive belt or fan guard while the unit is operating.
• When working on this equipment, remain alert at all times. Never work on the equipment when ph ysically or men-
tally fatigued.
• Inspect the generator regularly, and contact the nearest Dealer for parts needing repair or replacement.
• Before performing any maintenance on the generator , disconnect its battery cables to prevent accidental start up.
Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first, then remove the POSITIVE, POS or (+) cable. When reconnecting the cables, connect the POSITIVE cable first, the NEGATIVE cable
last.
• Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may
result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.
1.2.2— Electrical Hazards
•
All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical
shock. Avoid contact with bare wires, terminals, connections, etc., while the unit is running. Ensure all appropriate covers, guards and barriers are in place, secured and/or locked before operating the generator. If work must
be done around an operating unit, stand on an insulated, dry surface to reduce shock hazard.
• Do not handle any kind of electrical device while standing in water , while b arefoot, or while hand s or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
• The National Electrical Code (NEC) requires the frame and external electrically condu ctive part s of the generator
to be connected to an approved earth ground. Local electrical codes also may require proper grounding of the
generator electrical system.
• After installing this home standby electrical system, the generator may crank and start at any time without warn-
ing. When this occurs, load circuits are transferred to the STANDBY (generator) power source. To prevent possible injury if such a start and transfer occur, always set the generator to the OFF mode, remove the 7.5A fuse
adjacent to the generator control pad, and disconnect the battery before working on equipment.
• In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not
possible, attempt to free the victim from the live conductor. AV OID DIRECT CONTACT WITH THE VICTIM. Use
a nonconducting implement, such as a dry rope or board, to free th e victim from the live conductor. If the victim is
unconscious, apply first aid and get immediate medical help.
• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock,
or may get caught in moving components causing injury.
1.2.3— Fire Hazards
•
For fire safety, the generator must be installed and maintained properly. Installation must always comply with
applicable codes, standards, laws and regulations. Adhere strictly to local, st ate and national electrical and b uild-
Installation Guidelines for Air-Cooled Generators 3
ing codes. Comply with regulations the Occupational Safety and Health Admini stration (OSHA) has established.
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Also, ensure that the generator is installed in accordance with the manufacturer’s instructions and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes, standards, laws and regulations.
• Keep a fire extinguisher near the generator at all times. Extinguishers rated “ABC” b y the National Fire Protection
Association are appropriate for use on the standby electric system. Keep the extinguisher properly charged and
be familiar with its use. Consult the local fire department with any questions pertaining to fire extinguishers.
1.2.4— Explosion Hazards
•
Do not smoke around the generator . Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result.
Keep the area surrounding the generator clean and free from debris.
• Gaseous fluids such as natural gas and liquid propane (LP) gas are extremely EXPLOSIVE. Install the fuel sup-
ply system according to applicable fuel-gas codes. Before placing the home standby electric system into service,
fuel system lines must be properly purged and leak tested according to ap plicable code. After inst allation, inspect
the fuel system periodically for leaks. No leakage is permitted.
1.3 — General Rules
• Follow all safety precautions in the Owner’s Manual, Installation Guidelines manual and other documents
included with your equipment.
• Refer to NFPA 70E for safety equipment required when working with a live system.
• Never energize a new system without opening all disconnects and breakers.
• Always consult your local code for additional requirements for the area in which the unit is being installed.
Improper installation can result in personal injury and damage to the generator. It may also result in
the warranty being suspended or voided. All the instructions listed below must be followed including
location clearances and pipe sizes.
1.3.1— Before You Begin
•
Contact the local inspector or City Hall to be aware of all federal, state and local codes that could impact the
installation. Secure all required permits before starting the job.
• Carefully read and follow all of the procedures and safety precautions detaile d in the inst allation guide. If any por-
tion of the installation manual, technical manual or other factory-supplied documents is not completely understood, contact a dealer for assistance.
• Fully comply with all relevant NEC, NFPA and OSHA st andards as we ll as all federal, st ate and local buildin g and
electric codes. As with any generator, this unit must be installed in accordance with current NFPA 37 and NFPA
70 standards as well as any other federal, state, and local codes for minimum distances from other structures.
• Verify the capacity of the natural gas meter or the LP tank in regards to providing sufficient fuel for both the gen-
erator and other household and operating appliances.
1.3.2— Standards Index
Applicable national, state or local laws, codes and regulations pertaining to the installation of engine-generator power
systems must be strictly complied with. Always use the current acceptable version or edition of the applicable code or
standard which applies to your jurisdiction. In the absence of pertinent local laws and standards, the following published booklets may be used as a guide (these apply to localities which recognize NFPA and IBC):
1. National Fire Protection Association (NFPA) 70: The NATIONAL ELECTRIC CODE (NEC) *
2. NFPA 10: Standard for Portable Fire Extinguishers *
3. NFPA 30: Flammable And Combustible Liquids Code *
4. NFPA 37: Standard for Stationary Combustion Engines And Gas Turbines *
4 Installation Guidelines for Air-Cooled Generators
5. NFPA 54: National Fuel Gas Code *
*
6. NFPA 58: Standard for Storage And Handling Of Liquefied Petroleum Gases *
7. NFPA 68: Standard On Explosion Protection By Deflagration Venting *
8. NFPA 70E: Standard For Electrical Safety In The Workplace *
9. NFPA 211: Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances *
10. NFPA 220: Standard on Types of Building Construction *
11. NFPA 5000: Building Code *
12. International Building Code **
13. Agricultural Wiring Handbook ***
14. Article X, NATIONAL BUILDING CODE, available from the American Insurance Association, 85 John Street,
New York, N.Y. 10038.
15. ASAE EP-364.2 Installation and Maintenance of Farm Standby Electric Power ****
This list is not all-inclusive. Check with the Authority Having Local Jurisdiction (AHJ) for any local codes or standards
which may be applicable to your jurisdiction. The above listed standards are available from the following internet
sources:
* www.nfp a.org
** www.iccsafe.org
*** www.rerc.org Rural Electricity Resource Council P.O. Box 309 Wilmington, OH 45177-0309
**** www.asabe.org American Society of Agricultural & Biological Engineers 2950 Niles Road, S t. Joseph, MI 9085
The installation of this product must comply strictly with applicable codes, standards and regulations.
This product can be installed by the homeowner. However, if you are uncomfortable with the skills or
tools required, have a qualified electrician or contractor perform the installation.
Installation Guidelines for Air-Cooled Generators 5
This page intentionally left blank.
6 Installation Guidelines for Air-Cooled Generators
Section 2 Unpacking and Inspection
2.1 — General
NOTE: After unpacking, carefully inspect the contents for damage. Thoroughly inspect the unit immediately
upon delivery to determine if any damage occurr ed in transit. Any claims for shipping damage need t o be filed
with the freight carrier as soon as possible. This is especially important if the generator is not be installed for
a period of time. Any shipping damage, whether obvious or not readily apparent, is not covered by the warranty.
• The standby generator set is ready for installation with a factory supplied and pre-mounted base pad and has a
weather protective enclosure tha t is intended for outdoor installation only.
• If any loss or damage is noted at time of delivery, have the person making the delivery note all damage on the
freight bill or affix their signature under the consignor’s memo of loss or damage.
• If a loss or damage is noted after delivery, separate the damaged materials and contact the carrier for claim pro-
cedures.
• “Concealed damage” is understood to mean damage to the contents of a package that is not evident at the time
of delivery, but is discovered later.
2.2 — Required Tools
• General SAE and Metric hand tools
– Wrenches
– Sockets
– Screwdrivers
• Standard electrician’s hand tools
– Drill and bits for mounting and routing conduits
• 4mm Allen wrench (for access to customer connections)
• 3/16 Allen wrench (test port on fuel regulator)
• Manometer (for fuel pressur e chec ks)
• Meter capable of measuring AC Voltage and Frequency
• Meter capable of measuring AC Current
Installation Guidelines for Air-Cooled Generators 7
Unpacking and Inspection
Wooden
Generator
Frame
15 kW
Lid
Front
Crating Clamps (4)
Access Panel
Pallet
15 kW
2.3 — Unpacking
1. Remove shipping carton. See Figure 2-1.
Figure 2-1. Unpack Generator
2. Remove four bolts with crating clamp s. Carefully lif t the ge nerator of f the wo oden p allet. Do NOT dra g the gener-
ator off the pallet or damage to the base will occur. See Figure 2-2.
8 Installation Guidelines for Air-Cooled Generators
Figure 2-2. Remove Crating Clamps
Unpacking and Inspection
65
3. The lid of the generator enclosure is locked. Open the side door compartment and carefully cut the cable strap to
release the keys from the circuit breaker switch. See Figure 2-3.
Figure 2-3. Open Side Door Compartment to Obtain Keys
4. The lid is secured by two locks, one on each side of the enclosure. For b est results, pr ess down on the lid d irectly
above the side lock, and while holding the lid down, use key to unlo ck the latch. Re pea t step on o pposite sid e of
enclosure.
NOTE: The lid may appear stuck if pressure is not applied as described. Always verify that the side locks are
unlocked before pulling up on lid.
5. Raise lid.
6. Lift front access panel straight up to disengage side hooks, and then outward away from unit.
7. Perform a thorough visual inspection for any hi dden dam age. Cont a ct the freight carrier if any damage is evident.
8. Remove and inventory loose parts. See Subsection 2.4 —Parts Shipped Loose.
Installation Guidelines for Air-Cooled Generators 9
Unpacking and Inspection
Connection Area (Under Control Pad)
Battery Compartment
Fuel
Loose Parts
Regulator
Fuel Inlet Connection
MAIN AC/Control Wiring Main AC/Control Wiring
Base Fascia (If Equipped)
Conduit Hole (1-1/4 inch) with Cap PlugConduit Hole (3/4 inch) with Cap Plug
Figure 2-4. Customer Connection Area/Loose Parts Location
9. Figure 2-4 illustrates the following:
• Customer connection area (beneath and behind the control pad)
• Fuel regulator
• Battery compartment
• Location of Loose Parts shipped
Figure 2-5. Generator Back View
10 Installation Guidelines for Air-Cooled Generators
2.4 — Parts Shipped Loose
Battery
Keys
Wire Shielding
Flexible Fuel Line
Rubber Mounts
(Cable Strapped to Battery Cable or Alternator Bolt)
MLCB Terminal Caps
Terminal Cap
Installation Guidelines
For
Automatic Standby Generator
15 kW Synergy EcoGen™
This manual should remain with the unit.
This manual must be used in conjunction
with the appropriate owner’s manual.
NOT INTENDED FOR USE IN CRITICAL
LIFE SUPPORT APPLICATIONS.
ONLY QUALIFIED ELECTRICIANS OR
CONTRACTORS SHOULD ATTEMPT
INSTALLATION!
DEADLY EXHAUST FUMES! OUTDOOR
INSTALLATION ONLY!
To locate in Spanish, go to http://www.generac.com/serviceͲsupport/productͲsupportͲlookup
To locate in French, go to http://www.generac.com/serviceͲsupport/productͲsupportͲlookup
Owner’s Manual
For
Automatic Standby Generator
15 kW Synergy EcoGen™
This manual should remain with the unit.
This manual must be used in conjunction
with the appropriate installation manual.
NOT INTENDED FOR USE IN CRITICAL
LIFE SUPPORT APPLICATIONS.
ONLY QUALIFIED ELECTRICIANS OR
CONTRACTORS SHOULD ATTEMPT
INSTALLATION!
DEADLY EXHAUST FUMES! OUTDOOR
INSTALLATION ONLY!
To locate in Spanish, go to http://www.generac.com/serviceͲsupport/productͲsupportͲlookup
To locate in French, go to http://www.generac.com/serviceͲsupport/productͲsupportͲlookup
Owner’s Manual
Installation Manual
MLCB Locking Mechanism
Rear Mounting
Brackets
Oil Drain Pump Kit
The generator is shipped with the following loose parts:
• Rubber Mounts (units that include fascia)
• Battery Terminal Cap
• Main Line Circuit Breaker (MLCB) Terminal Caps
• Main Line Circuit Breaker (MLCB) Locking Mechanism
• Keys
• Flexible Fuel Line
• Oil Drain Pump Kit
• Wire Shielding to separate AC from DC control wires
• Rear Mounting Brackets (2)
• Installation/Owner’s Manuals (CD if applicable)
Unpacking and Inspection
Installation Guidelines for Air-Cooled Generators 11
Figure 2-6. Loose Parts
Unpacking and Inspection
This page intentionally left blank.
12 Installation Guidelines for Air-Cooled Generators
Section 3 Site Selection and Preparation
These guidelines are based upon fire
testing of the generator enclosure and
the manufacturer’s requirement for air
flow for proper operation. Local codes
may be different and more restrictive
than what is described here.
Clearance from the ends and front of the generator must be 36 in (914 mm). This would
include shrubs, bushes or trees. Clearance at
the top should be a minimum of 60 in (1524
mm) from any structure, overhang or projections from the wall. The generator should not
be placed under a deck or other structure that
is closed in and would limit or constrain air flow.
No operable windows or openings in the wall permitted
within 5 ft (1.52 m) from any point of the generator.
Clearance from operable
windows, doors or any
openings in the wall.
Top of Generator
60 in (1524 mm) Minimum
60 in (1524 mm)
18 in (457 mm)
Generator
Minimum
Required
Minimum From Ends
Existing Wall
Clearance from operable
windows, doors or any
openings in the wall.
to openings in walls
36 in
(914 mm)
36 in
(914 mm)
36 in
(914 mm)
60 in (1524 mm) 60 in (1524 mm)
18 in (457 mm)
Minimum Distance
3.1 — Site Selection
Figure 3-1. Installation Guidelines
Installation Guidelines for Air-Cooled Generators 13
Site Selection and Preparation
Install the generator outdoors in its pr otective enclosure where adequ ate cooling and ventilating air is always available.
Also consider these other factors:
• Installation must strictly comply with NFPA 37, NFPA 54, NFPA 58, and NFPA 70 standards.
• Install the generator where air inlet and outlet openings will not be obstructed by leaves, grass, snow, etc. If pre-
vailing winds can cause blowing or drifting, use a windbreak for protection.
• Install the generator on high ground where rising water levels will not endanger it. The generator must not oper-
ate in or be subjected to standing water.
• Allow sufficient room on all sides of the generator for maintenance and servicing . Install the unit in accordance
with current applicable NFPA 37 and NFPA 70 standards, as well as any other federal, state and local codes for
minimum distances from other structures. DO NOT install under wooden decks or structures unless there is at
least 5 feet (1.52 m) of clearance above the generator, 3 feet (0.91 m) of clearance at sides and front, and a minimum of 18 inches (457 mm) of clearance at the back of the unit.
• Install where rain gutter down spouts, roof ru n-of f, landscape irrigation, water sprinklers or sump pump discharge
does not flood, spray, or splash the enclosure, particularly air inlet or outlet openings.
• Install where services will not be affected or obstructed, including concealed, underground or covered services
such as electrical, fuel, phone, air conditioning or irrigation. This could affect Warranty Coverage.
• Where strong prevailing winds blow from one direction, face the generator air inlet openings to the prevailing
winds.
• Install the generator as close as possible to the fuel supply source to reduce the length of piping required.
REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE AND LOCATION.
• If applicable, install the generator as close as possible to the transfer switch. REMEMBER THAT LAWS OR
CODES MAY REGULATE THE DISTANCE AND LOCATION.
• Install the generator on a level surface. The generator must be level within a 0.5 inches (13mm) all around.
• The generator is typically placed on a concrete pad, comp acted pea gravel, o r crushed stone. Check local code s
to see what type is required. If a concrete pad is required, follow all federal, state and local codes.
3.1.1— Installation Guidelines
The National Fire Protection Association has a standard for the installation and use of stationary combustion engines.
That standard is NFPA 37, its requirements limit the spacing of an enclosed generator set from a structure or wall (Figure 1.10).
NFPA 37, Section 4.1.4, Engines Located Outdoors: Engines, and their weatherproof housings if provided, that are
installed outdoors shall be located at least 5 ft (1.52 m) from openings in walls and at least 5 ft (1.52 m) from structures
having combustible walls. A minimum separation shall not be required where either of the following conditions exist:
1. The adjacent wall of the structure has a fire resistance rating of at least 1 hour.
2. The weatherproof enclosure is constructed of noncombustible materials and it has been demonstrated that a fire
within the enclosure will not ignite combustible materials outside the enclosure.
Annex A — Explanatory Material
A4.1.4 (2) Means of demonstrating comp lia nc e ar e by me a ns of full scale fire test or by calculation procedures.
Because of the limited spaces that are frequently available for installation, it has become apparent that exception (2)
would be beneficial for many residential and commercial installations. With that in mind, the manufacturer contracted
with an independent testing laboratory to run full scale fire tests to assure that the enclosure will not ignite combustible
materials outside the enclosure.
NOTE: Southwest Research Institute testing approves 18 inches (457 mm) installation minimum from structure. Southwest Research is a nationally recognized third party testing and listing agency.
The criteria was to determine the worst case fire scenario within the generator and to determine the ignitability of items
outside the engine enclosure at various dist a nces. The enclosur e is constructed of non-c ombustible materials, and th e
results and conclusions from the independent testing lab indicated that any fire within the generator enclosure would
not pose any ignition risk to nearby combustibles or structures, with or without fire service personnel response.
14 Installation Guidelines for Air-Cooled Generators
Site Selection and Preparation
*
Figure 3-2. Southwest Research Institute Decal
Southwest Research Institute Decal (located inside the generator, next to the generator’s data decal)
http://www.swri.org/4org/d01/fire/listlab/listprod/director.htm
Based on this testing and the requirement s of NFPA 37, Sec 4.1.4, the guidelines for installation of the generators listed above are changed to 18 inches (457 mm) from any point of the generator enclosure to a stationary
wall, building or structure. The required distance for maintenance and airflow clearance, the area above the genera-
tor should be at least 5 feet (1.52 m) with a minimum of 3 feet (0.91 m) at the front and ends of the enclosure. This
would include trees, shrubs and bushes. Vegetation not in compliance with these clearance parameters could obstruct
air flow. In addition, exhaust fumes from the generator could inhibit plant growth. For details, see the installation drawing within the owner’s manual and Figure 3-1.
Generator exhaust contains DEADLY carbon monoxide gas, which can cause unconsciousness or death. Do n ot place
the unit near windows, doors, fresh air intakes (furnaces, etc.) or any openings in the building or structure, including
windows and doors of attached garage.
If the generator is not set to the OFF mode, it can crank and start as soon as the battery
cables are connected.
3.2 — Site Preparation
• Locate the mounting area as close as possible to the electrical loads that are to be powered by the generator an d
fuel supply.
• Leave adequate room around the area for service access (check local code), and place high enoug h to keep out
rising water.
• Choose an open space that provides adequate and unobstructed airflow.
• Position the unit so air vents will not become clogged with leaves, grass, snow, or debris. Be sure exhaust fumes
will not enter the building through eaves, windows, ventilation fans or other air intakes (see the “Site Selection”
section).
• Select a gravel or concrete base depending upon local code requirements.
Installation Guidelines for Air-Cooled Generators 15
Site Selection and Preparation
3.2.1— Material Sufficient for Level Installation
•
Dig a rectangular area approximately 5 inches (127 mm) deep and about 6 inches (152 mm) longer and wider
than the footprint of the generator. Fill with pea gravel, crushed stone or any other non-combustible material sufficient for level installation. Compact and level the material. A concrete pad can be poured if required. Make the
concrete pad 4-5 inches (102-127 mm) thick and extend 6 inches (152 mm) beyond the outside perimeter of the
generator in all directions.
NOTE: If a concrete pad is required, follow all applicable Federal, State and local codes.
Figure 3-3. Compacted Gravel Site
Figure 3-4. Concrete Pad Site
16 Installation Guidelines for Air-Cooled Generators
Section 4 Generator Placement
Rear Mounting Brackets
Front Mounting Holes
4.1 — Generator
With the Site Selection and Preparation performed, proceed with placement and installation of the generator itself.
See Figure 4-1. All air-cooled generators come with a composite pad. The composite pad elevates the generator and
helps prevent water from pooling around the bottom. Place the generator (with composite pad) on a concrete pad or
four inches (102 mm) of compacted pea gravel. Check local codes to see what type of site base is required. If a concrete pad is required, all federal, st ate and local codes mu st be followed. Pla ce the gen erator on the mounting p ad an d
position correctly based on the dimensional information presented in Subsection 3.1 — Site Selection.
NOTE: Generator must be level within 0.5 inches (13 mm).
NOTE: If the composite pad is removed for concrete mounting, the fascia kit will not fit.
Figure 4-1. Composite Pad
Four mounting points are provided fo r securing the gene rator to concrete- two hole s at the inside fron t of the enclosure
and two outside rear mounting brackets. See Figure 4-2.
NOTE: Use the template at the top of the generator carton to mark the concrete p ad for drilling of the two front
mounting holes. For dimensions of the two rear mounting holes, see Subsection 10.1 — Installation Drawing.
NOTE: Use the zinc plated mounting brackets provided with the other loose parts shipped. Do not use the
brackets from the shipping pallet to anchor the generator to the concrete pad.
Figure 4-2. Generator Mounting Points
Installation Guidelines for Air-Cooled Generators 17
Generator Placement
A
B
C
4.2 — Fascia Skirt Installation (If Applicable)
Install base fascia as follows:
1. Remove four rubber mounts from Owner’s Manual bag.
2. Screw two rubber mounts into threaded holes of end piece. See A of Figure 4-3.
3. Snap end piece into side piece. See B of Figure 4-3.
4. Fit rubber mounts in end piece into lifting holes at base of generator. See C of Figure 4-3.
5. Repeat steps 2-4 to install second end and side pieces.
6. To complete assembly, snap end pieces into side pieces at opposite corners of fascia.
Figure 4-3. Install Fascia Skirt
18 Installation Guidelines for Air-Cooled Generators
Section 5 Fuel Conversion/Gas Connections
5.1 — Fuel Conversion
Although the generator is configured at the factory for operating on natural gas, provision is made to switch over to LP
Vapor.
NOTE: The fuel selection (NG/LP) can be changed using the Installation Wizard at initial power up, or by
accessing the EDIT Menu thereafter.
NOTE: The orange fuel conversion knob is located on the engine at the top of the fuel mixer.
To change fuel selection, rotate fuel conversion knob to the desired fuel source (in the direction of the arrow) until it
stops. Fuel knob rotates 180° and slides into mixer body when converting to LP gas.
NOTE: If experiencing difficulty turning knob to LP position, lightly tap on knob before turning. Do not use a
pliers!
Figure 5-1. Fuel Conversion Knob
(As Viewed From Generator Air Box Side)
5.2 — Fuel Requirements and Recommendations
With LP gas, use only the vapor withdrawal system, which uses the vapors formed above the liquid fuel in the storage
tank.
The engine has been fitted with a fuel carburetion system that meets the specifications of the 1997 California Air
Resources Board for tamper-proof dual fuel systems. The unit will run on natural gas or LP gas, but has been factory
set to run on natural gas. Should the primary fuel need to be changed to LP gas, the fuel system needs to be reconfigured. See the Fuel Conversion section for instructions on converting the fuel system.
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 (93.15 megajoules per cubic meter) for LP gas. Ask the fuel
supplier for the Btu content of the fuel.
NOTE: Required fuel pressure for natural gas is 3.5-7 inches water column (7-13 mm mercury). Required fuel
pressure for LP vapor is 10-12 inches water column (19-22 mm mercury).
NOTE: The primary regulator for the propane supply is NOT INCLUDED with the generator.
Installation Guidelines for Air-Cooled Generators 19
Fuel Conversion/Gas Connections
*
NOTE: All pipe sizing, construction and layout must comply with NFPA 54 for natural gas applications and
NFPA 58 for liquid propane applications. Once the generator is installed, verify that the fuel pressure NEVER
drops below its required fuel pressure rating. For more information regarding NFPA requirements, refer to
www.nfpa.org.
Prior to installation, consult local fuel suppliers or the fire marshal for applicable codes and regulations. Local codes
mandate correct routing of gaseous fuel line piping around gardens, shrubs and other landscaping.
Special considerations with regard to the flexibility and strength of piping and connections may be required when
installing the unit where local conditions are prone to flooding, tornadoes, hurricanes, earthquakes and/or unstable
ground.
Use an approved pipe sealant or joint compound on all threaded fittings.
Purge and leak test all installed gaseous fuel pip ing prior to initial start-up in accordance with all local codes, stand ards
and regulations.
5.3 — Fuel Consumption
The following are approximate values only. Use the appropriate specification sheet or Owner’s Manual for specific values.
Natural Gas LP Vapor
Generator
1/2 Load Full Load 1/2 Load Full Load
15 kW EcoGen 128 / 3.63 302 / 8.55 1.28 / 4.85 2.62 / 9.92
* Natural gas is in cubic feet per hour / cubic meters per hour.
** LP is in gallons per hour / liters per hour.
*** Values given are approximate.
Verify that the gas meter is capable of providing sufficient fuel flow to include household appliances and all other loads.
Gaseous fuels such as natural gas and liquid propane gas are highly explosive. Any spark
can ignite these fuels and cause an explosion. No leakage of fuel is permitted. Natural gas,
which is lighter than air , tends to co llect in high areas. LP gas i s heavier than air and tends t o
settle in low areas.
NOTE: Install a minimum of one approved full flow manual shut-off valve in the gaseous fuel supply line. The
valve must be easily accessible. Check with local codes to determine proper location.
NOTE: The gas supply and pipe MUST be sized at 100% Load BTU / megajoule rating.
5.4 — Fuel Line Sizing
1. Determine required pipe size. Refer to NFPA 54 for NG or NFPA 58 for LP.
2. Refer to the Owner’s Manual for the proper BTU / megajoule and required gas pressures. To calculate BT U or
Megajoules, proceed as follows:
• Natural Gas: BTU = Cubic feet / hour x 1000
Megajoules = Cubic meters / hour x 37.26
• Liquid Propane Vapor: BTU = Cubic feet / hour x 2500
Megajoules = Cubic meters / hour x 93.15
3. Measure the distance from the generator to the gas source. The generator should be plumbed directly from the
fuel source and not off the end of an existing system.
20 Installation Guidelines for Air-Cooled Generators
Fuel Conversion/Gas Connections
4. When measuring pipe length, add 2.5 feet (0.76m) for each angle or bend in the pipe run and add that to the
overall pipe distance.
5.4.1— Natural Gas Pipe Sizing
The following table indicates the maximum length (measured in feet / meters) allowed for various pipe sizes. The pipe
sizes are measured by inside diameter (ID) to include any fittings, valves (must be full flow), elbows, tees or angles.
Add 2.5 feet (0.76 m) to the overall distance for each bend, tee or angle in the pipe run.
NOTE: Tables based on Schedule 40 black pipe.
Allowable Pipe Distances (feet / meters)
Pipe Size
(in. / mm)
15 kW EcoGen
For 5-7 inches of water column (9-13 mm of mercury).
1 / 25 1.25 / 32 1.5 / 38
20 / 6 100 / 30 200 / 60
Allowable Pipe Distances (feet / meters)
Pipe Size
(in. / mm)
15 kW EcoGen
For pressures 3.5 - 5 inches of water column (7 - 9 mm of mercury).
1 / 25 1.25 / 32 1.5 / 38
10 / 3 60 / 18 125 / 38
5.4.2— LP Vapor Pipe Sizing
The table indicates the maximum length (measured in feet / meters) allowed for various pipe sizes. The pipe sizes are
measured by inside diameter (ID) to include any fittings, valves (must be full flow), elbows, tees or angles. Add 2.5 feet
(0.76 m) to the overall distance for each bend, tee or angle in the pipe run.
NOTE: Pipe sizes are using a second stage regulator.
Allowable Pipe Distances (feet / meters)
Pipe Size
(in. / mm)
15 kW EcoGen
Installation Guidelines for Air-Cooled Generators 21
0.75 / 19 1 / 25 1.25 / 32
250 / 76 70 / 21 350 / 106
Fuel Conversion/Gas Connections
AB
5.4.3— Gas Installation Summary
Mistakes frequently occur when sizing gas pipe. A properly sized gas pipe is critical to the proper operation of the generator. The generator inlet size has no bearing on the proper gas pipe size. If using a piping method other than black
pipe, refer to local codes and the pipe manufacturer’s specifications for sizing and installation information.
IMPORTANT: Size the gas supply and pipe at 100% Load BTU / megajoule rating.
5.5 — Installing and Connecting Gas Lines
1. Both natural gas and LP Vapor are highly volatile substances, so strict adherence to all safety procedures,
codes, standards and regulations is essential.
2. Gas line connections should be made by a certified plumber familiar with local codes. Always use AGA-approved
gas pipe and a quality pipe sealant or joint compound.
3. Verify the capacity of the natural gas meter or the LP tank in regards to providing sufficient fuel for both the gen-
erator and other operating appliances.
• Fuel Regulator installed per laws or regulator manufacturer’s specifications
• AGA approved gas pipe
• Flexible fuel line
– Do not bend!!!
– Install horizontally
– Do not attach directly to generator
– Check all connections for leaks
• Sediment trap near generator (if applicable or required by code)
• Full flow rated shut-off near generator per local jurisdiction or code
4. Most applications require an external manual shutoff valve on the fuel line.
Figure 5-2. Manual Shutoff V alve (A),
Accessory Valve with Manometer Port (B)
NOTE: The manometer port on the Generac accessory valve allows fuel pressure checks to be performed
without opening the generator enclosure.
22 Installation Guidelines for Air-Cooled Generators
Figure 5-3. Sediment Trap
Sediment
Trap
Fuel Conversion/Gas Connections
Figure 5-4. Incorrect Routing of Flexible Hose
5. When connecting the gas line to the generator, use the provided section of UL Listed or AGA-approved flexible
fuel line in accordance with local regulations. The flexible fuel line ensures that vibration from the generator does
not cause a gas leak at one of the connection points. It is important that the line be installed with as few ben ds as
possible. Configure the sediment trap (if required) as shown.
6. Always install the flexible fuel line horizontally. Never bend to avoid using a pipe elbow. Bending the flexible fuel
line reduces its ability to absorb vibrations and may constrict fuel flow. See Figure 5-4.
7. Check for leaks by spraying all connection points with a solution of dish washing soap and water. Leaks exist If
bubbles are observed or if the solution is blown away.
Installation Guidelines for Air-Cooled Generators 23
Fuel Conversion/Gas Connections
Top Gas Pressure Test Port
Fuel Pressure Regulator
Gas Pressure Manometer
0000001
Manual
Shut Off Valve
Sediment Trap
Gas Main
2-5 PSI
Size Gas Meter for
Generator Load Plus All
Appliance Loads
NG BTU = Cubic Feet/Hour X 1000
Fuel Pressure
3.5-7” Water Column
Flexible Fuel Line
With Pressure Port
Check Distance with Gas Provider
BTU and Pressure Decal
Megajoules = Cubic Meters/Hour X 37.26
For Underground Installations,
Verify Piping System
for Code Compliance
8. Check gas pressure at the generator fuel pressure regulator as follows:
– Close gas supply valve.
– Remove top test port from fuel pressure regulator.
– Install gas pressure tester (manometer). See Figure 5-5.
– Open gas supply valve.
– Verify that fuel pressure is within specification.
– Close gas supply valve.
Figure 5-5. Check Pressure with Manometer
Figure 5-6. Typical Natural Gas Installation
24 Installation Guidelines for Air-Cooled Generators
Fuel Conversion/Gas Connections
Manual
Shut Off Valve
Sediment Trap
With Pressure Port
BTU and
Fuel Tank
Check Distance with LP Provider
Pressure Decal
Check Distance with
Regulator Manufacturer
Size Fuel Tank Large Enough to Provide
Required BTUs for Generator and ALL
Connected Appliance Loads. Be Sure to
Correct for Weather Evaporation.
Flexible
Fuel Line
Manual
Shut Off Valve
LP BTU = Cubic Feet/Hour X 2500
Megajoules = Cubic Meters/Hour X 93.15
Secondary
Fuel Pressure
Regulator
Primary Fuel Pressure Regulator
Per LP Provider
Figure 5-7. Typical LP Vapor Installation
NOTE: When sizing a secondary regulator for LP or high pressure natural gas applications be sure to note the
maximum individual load capabilities which will be lower than total ca p acity. This could impact generator starting performance if sized too small.
NOTE: Do not reduce the fuel pipe size exiting the secondary r egulator unless ne cessary to acc ommodate the
1/2 inch flexible fuel line shipp ed with the generator. This may potentially cause starting or performance
issues.
NOTE: Even if the generator is running smoothly, a drop in gas pressure indicates that the supply is barely
adequate to supply the generator’s needs. Changes in the genera tor load, or additional gas demand by other
appliances may affect the generator’s perfor mance . Verify gas pressure and pipe sizing. Unhook the manometer and reinstall the port plug.
Installation Guidelines for Air-Cooled Generators 25
Fuel Conversion/Gas Connections
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26 Installation Guidelines for Air-Cooled Generators
Section 6 Electrical Connections
6.1 — Generator Connections
NOTE: Wiring must be performed in accordance with local jurisdiction and codes.
1. Remove the appropriate Main AC/Control Wiring knock-out plug at back of generato r.
2. Install the generator feeder and control wiring between the generator and inverter or electrical loads to be pow-
ered by the generator per the applicabl e NEC codes for the wiring method sele cted. For knock- out plug locations
(verify specific transfer wiring and connections per model), see Figure 2-5.
NOTE: This wiring can be run in the same conduit if the appropriate insulation rated wire is used.
3. Seal the conduit at the generator in compliance with any codes.
4. Strip insulation from wire ends. Do not remove excessive insulation.
5. To connect the control wires, push down on the spring loaded connection point with a flat head screwdriver , insert
wire and release.
NOTE: No wire insulation should be in the connection point, only bare wire.
NOTE: The system is equipped with a 2-wire start to facilitate connection to the inverter system.
6.2 — Control Wiring
Control and 2-wire Start Length and Size
Maximum Wire Length Recommended Wire Size
1-115 ft (1-35 m) No. 18 AWG
116-185 ft (36-56 m) No. 16 AWG
186-295 ft (57-89 m) No. 14 AWG
296-460 ft (90-140 m) No. 12 AWG
Control Pad Connections
Terminal Numbering Decal Wire Numbers
B Blue #3 T1 - Fused 120VAC for Battery Charger
(see NOTE beneath Fig. 6-1 on the following page)
C Black #3 0 - DC (-) Common Ground Wire
2-wire Start Wire Con nections
Wire Connection Location
178 Female Faston
183 Female Faston
Installation Guidelines for Air-Cooled Generators 27
Hanging from controller above battery compartment
(see Figure 6-2)
Electrical Connections
Large Ground
2/0 to 14 AWG:
120 in-lbs (14 Nm)
4-6 AWG: 35 in-lbs (4 Nm)
8 AWG: 25 in-lbs (3 Nm)
10-14 AWG: 20 in-lbs (3 Nm)
Wire 178
Wire 183
Figure 6-1. Control Wiring Torque Specifications
NOTE: To separate low voltage from high voltage wires, unless NEC Section 300.3(c)(1) requirements are met,
run 2-wire start and T1 wires through wire shielding provided (see Subsection 2.4 —Parts Shipped Loose).
NOTE: Regardless of whether unit is running or not, keep T1 conne cted and energized with 120 VAC to keep
battery charged.
Figure 6-2. 2-wire Start Wire Connections
28 Installation Guidelines for Air-Cooled Generators
Electrical Connections
+
6.3 — Main AC Wiring
Figure 6-3. Main AC Wiring
NOTE: Main AC (E1, E2 and Neutral) wiring must be in accordance with local jurisdiction and codes.
1. Strip insulation from wire ends. Do not remove excessive insulation.
2. Remove two cap plugs located behind the breaker door and to the right of the Main Breaker.
3. Loosen the lugs of the Main Breaker through the access holes.
4. Insert a power wire (E1 or E2) through the opening in the back cover and into the bottom lug. Torque to the
proper specification.
NOTE: Remove three screws inside the top of the breaker panel (behind the breaker door), and carefully pull
out entire breaker box. When reinstalling, be sure that tabs at the bottom lock into place.
5. Connect the Neutral wire to the Neutral Lug and tighten to specifica tion. See Figure 6-1.
6. Connect the Ground wire to the Ground Lug and tighten to specification. See Figure 6-1.
NOTE: Neutral Bonding - For installations that require the neutral to be bonded to the ground, this is to be
done on the customer connections terminals inside the generator. Connect a suitably sized wire from the neutral bar to the ground bar. This is normally required when the generator is the source in a separately derived
system. It is not required when the generator is a backup source in a utility supplied electrical system with a 2pole transfer switch. See Figure 6-1.
NOTE: Torque all wiring lugs, bus bars and connection points to the proper torque specifications. Torque
specifications for the Main Line Circuit Breaker (MLCB) can be found on a decal located on the inside of the
Main Line Circuit Breaker Door.
6.4 — 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.
The secondary fan continues to operate for up to one hour after the generator is shut down. Proper cooling must occur
before removing either battery connections or 7.5 amp fuse for maintenance or other service activity.
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 in the controller is removed. To prevent hand injury,
always exercise caution when working near the AVR fan housing.
Installation Guidelines for Air-Cooled Generators 29
Electrical Connections
$
12VDC
Red (+)
Red Lead
From Starter
Contactor
Black (-)
Black Lead
To Frame
NOTE: The AVR cooling air inlet includes a filter. Verify the filter is installed and properly seated at time the
unit is installed. Check t he filter at regula r maintenance inter vals to verify p roper airflow. See the Maintenance
section of the Owner’s Manual for details.
6.5 — Battery Requirements
Group 26R, 12V, 525 CCA (Minimum CCA).
6.6 — Battery Installation
Proceed as follows:
1. Verify that the generator is turned OFF. A red LED on the control pad illuminates to confirm that the system is in
the OFF mode.
2. Pull up rubber flap covering fuse holder and remove 7.5 amp fuse.
3. Check the fluid level of unsealed batteries. If necessary, fill with distilled water only. DO NOT use tap water.
4. Check the state of charge using a Digital Multime ter. Recharge and retest if state of charge is below manufac-
turer's recommendations. Replace battery if necessary.
5. Install battery onto battery tray.
Always connect the positive battery cable first. If the positive cable should contact ground with the
negative cable installed, the resulting sparks may cause a battery explosion which could result in serious injury.
6. Install battery positive cable (red) to battery positive (+) terminal. See Figure 6- 4.
7. Install battery negative cable (black) to battery negative (-) terminal.
NOTE: Apply Dielectric grease to battery terminals to prevent corrosion.
8. Install red cover over battery positive (+) terminal.
Figure 6-4. Battery Cable Connections
NOTE: A Cold Weather Kit is required in areas where temperatures regularly fall below 32 °F (0 °C). The kit
includes a pad type battery heater and engine oil warmer to aid cold climate starting. The kit can be obtained
through Generac.com or an independent authorized service dealer.
30 Installation Guidelines for Air-Cooled Generators
Section 7 Operation
*
7.5 Amp Fuse
and USB Port
(Under Flap)
Side Lock
Generator Disconnect
Circuit Breaker
Side Door Compartment
LCD Screen
Control Pad
7.1 — Control Pad
The control pad is intended for use by qualified service personnel only.
See Figure 7-1. The control pad is located under the lid of the enclosur e. The lid is secu re d by two locks, one on e ach
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. Always unlock both the left and rig ht side
locks before attempting to lift the lid.
NOTE: The lid may appear stuck if pressure is not applied as described. Always verify that the side locks are
unlocked before pulling up on lid.
To remove the front access panel, lift it straight up to disengage side hooks, and then outward away from unit.
When closing the unit, remember to lock both left and right side locks.
Figure 7-1. Control Pad and Side Compartment
Installation Guidelines for Air-Cooled Generators 31
Operation
*
LCD Screen
AUTO
UP ARROW
ENTER
ESCAPE
OFF
MANUAL
DOWN ARROW
Green
LED
Blue
LED
Red
LED
With the control pad set to AUT O, the engine may crank and st art at any time without wa rning.
To prevent possible injury that might occur during sudden starts, always set the control pad
to OFF and remove the 7.5 amp fuse before working on or around the generator or the electrical loads that are to be powered by the generator. For added security, place a DO NOT OPERATE tag or placard at both the control pad and the electrical loads that are to be powered by
the generator.
NOTE: Never run the generator with any access panel removed.
Figure 7-2. Control Pad and LCD Screen
7.2 — Auto/Manual/Off
Feature Description
AUTO
MANUAL Press to crank and start engine. Blue LED illuminates to confirm that system is in MANUAL mode.
OFF Press to shut down engine, if running. Red LED illuminates to confirm that system is in OFF mode.
Press to activate fully automatic operation. Green LED illuminates to confirm that system is in AUTO mode.
Transfer to standby power occurs if 2-wire start signal is enabled.
32 Installation Guidelines for Air-Cooled Generators
7.3 — Menu Navigation
Feature Description
System Menus
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
HOME Screen
MAIN MENU
ESCAPE Used to abort a routine or back up to the preceding menu.
ENTER Used to make a selection or save an entry.
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.
In the event of multiple Alarms/Warnings, the next message is then displayed. The highest prior it y al arm is
always displayed first.
Enables the operator to navigate the software using UP ARROW, DOWN ARROW, ENTER and ESCAPE.
The Main Menu can be accessed from any sub menu by consecutively pressing ESCAPE. Each time
ESCAPE is pressed, the preceding menu is displayed. The Main Menu is reached when the System,
Date/Time, Battery, and Sub Menus are displayed.
Navigation
Operation
UP ARROW
DOWN ARROW
NOTE: Pressing any button on the control pad illuminates the backlight for 30 seconds. The backlight also illuminates for 30 sec-
onds whenever an active Alarm/Warning message is displayed.
Used to move forward or backward from menu to menu or to scroll forward or backward (increment or decrement) through available selections.
7.4 — Change Time and Date
To change the time and date, see the Navigation Menu in Figure 7-4. If power is lost (battery is disconnected/reconnected, 7.5 amp fuse is removed/installed, etc.), the display automatically prompts the user for the Time and Date. All
other information is retained in memory.
7.5 — Programmable Timers
7.5.1— Dealer Programmable
NOTE: A dealer password is required.
7.5.1.1—High Run Speed Timer
A programmable high run speed timer is provided. The timer controls the le ngth of time the generator ru ns at maximum
speed after application of a large load (such as an air conditioner). The time can be increased to prevent the potential
cycling of engine RPM as loads turn on and of f. For exampl e, if the timer is currently set to ten minutes, and the nor mal
AC cycling time is 15 minutes, increasing the timer to 20 minutes would prevent the engine speed from ramping up and
down every ten minutes between AC cycles (even though fuel consumption would increase).
7.6 — USB Port for Firmware Updates
A USB port is located beneath the rubber flap adjacent to the control pad, and is provided for firmwar e updates. Firmware updates must be performed by an Authorized Service Dealer.
NOTE: The USB port is intended for use with a USB thumb drive only. The USB port is not intended for
charging devices such as phones or laptops. Do not connect any consumer electronics to the USB port.
Installation Guidelines for Air-Cooled Generators 33
Operation
*
"Generator"
"AcƟve"
"Install Wizard"
"......."
"ESC to run in manual"
"NOT ACTIVATED !"
""
"To acƟvate go to"
"- English +"
"- Espanol +"
"- Francois +"
"<- XX ->"
Note: Set Fuel Type
"Serial 1234567890"
"Wrong Passcode"
"Try Again"
"- LP +"
"- NG +"
"Select Minute (0-59)"
Note: Set Generator Time
Note: Finishes at status screen
ENTER
ENTER
This will only come up the Įrst Ɵme the generator is powered. If ESC is pressed to skip the
acƟvaƟon process, the baƩĞry must be disconnected to allow acƟvaƟon again and this process
will reiniƟalize. If power is removed aŌĞr a successful acƟvaƟon, the data is remembered and the
acƟvaƟon steps are skipped.
ENTER
3sec delay
ESCAPE
ENTER
wrong entry
IF NOT YET ACTIVATED
ENTER
Note1: Language only shows up
Įƌst Ɵme it is powered unless
enter is pressed to skip through
the install wizard
Note1: Can run in MANUAL only if
NOT ACTIVATED
Note2: Must disconnect baƩĞry to
allow acƟvaƟon again
7.7 — Before Initial Start-Up
NOTE: This unit has been run and tested at the factory prior to shipment and does not require any break-in.
Operating the engine with the oil level below the ADD mark on the dipstick can cause
engine damage.
NOTE: This unit comes filled with 5W - 30 full synthetic oil from the factory. Check the oil level and add the
appropriate viscosity and amount if necessary.
7.7.1— Installation Wizard
The insulation wizard comes up the first time the generator is powered, it allows the user to input generator settings
upon power up. See Figure 7-3.
The Installation Wizard will start every time power (both AC and DC) are removed and then re-applied.
"Language"
"<- XXXXX ->"
"- Portugues +"
" Fuel SelecƟon"
"Select Hour (0-23)"
"Select Month (1-12)"
"Select Date (1-31)"
"Select Year (0-99)"
"XXXXX"
"XXXXX"
"AcƟvate me (ENT) or"
"www.acƟvategen.com"
"PASSCODE xxxxx"
Figure 7-3. Installation Wizard Menu
34 Installation Guidelines for Air-Cooled Generators
Operation
ECOGEN HSB MENU MAP
UP ARROW =
+
DOWN ARROW = -
“Run Log”
ESC
ENTER
ENTER
SYSTEM
BATTERY
DATE/TIME
SUB MENUS
HISTORY
EDIT
MAINT
DEALER
EXAMPLE:
Inspect Battery 200 RnHr or 12/27/13
and
Next Maintenance 200 RnHr or 12/27/13
Firmware Update
Å
Press Enter
Æ
Current Date/Time
02/14/13 07:40
ESC
ESC
ESC
ENTER
ENTER
Current Date/Time
Å
2/12/13 12:22
Æ
ESC ENTER
ESC
ESC
ESC ESC
ENTER
ENTER
ESC
ESC
ESC
ENTER
ENTER
ESC
ESC
ESC
ENTER
MAINT:
Maint. Log
Run Hrs
Scheduled
ENTER
ESC
ENTER
ENTERENTER
ENTER
ENTER
Select Month (1-12)
- 2 +
Run Hours (H)
0.0
ENTER
Select Date (1-31)
- 13 +
ENTER
Select Year (0-99)
- 13 +
ENTER
ENTER
ENTER
ESC
Switched to “OFF”
Hours of Protection
0 (H)
Access Requires Password
Language
Å
English
Æ
Fuel Selection
Å
NG or LP
Æ
Possible Message(s)
Corrupted File
Invalid File
File Not Found
Unsupported Device
"Current:V XXXX "
"USB: V XXXX"
"Are You Sure?"
"- Yes or No +"
ESC
ENTER
Firmware Update
Å
Insert USB
Æ
“Alarm Log”
- Alarm Log +
- Run Log +
- 1 thru 50 +
- 1 thru 50 +
ESCENTER
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"
Warning Message(s)
"Low Battery"
"Exercise Set Error"
"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-Utility Lost
Running-Remote Start
Running-2 Wire Start
Running - Exercise
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
ESC
Select Hour (0-23)
- 14 +
Language
+ English -
Fuel Selection
+ NG or LP -
Language
+ Espanol -
Language
+ Francais -
Language
+ Portuguese -
+
-
+
-
+
-
+
Battery Condition
“Good” “Inspect Battery” or “Check Battery”
For complete listing of alarms and warnings,
see Section 8 Troubleshooting.
Installation Guidelines for Air-Cooled Generators 35
Figure 7-4. Navigation Menu
Operation
7.7.2— Before Starting
Complete the following:
1. Verify that the generator is OFF. A red LED illuminates to confirm that system is in OFF mode.
2. Move the Generator Disconnect Circuit Breaker switch to the OFF (Open) position.
3. Turn off all circuit breakers/electrical loads that are to be po wer e d by th e ge ne r ato r.
4. Check engine oil level. If necessary, add oil until the level is at or near the FULL mark on the dipstick. DO NOT
OVERFILL.
5. Check fuel supply. Gaseous fuel lines must be properly purged and leak tested in accordance with applicable
fuel-gas codes before use. Verify that all fuel shut off valves in the fuel supply lines are open.
During initial start up only, the generator may exceed the normal number of start attempts and experience an “overcrank” alarm. This is due to accumulated air in the fuel system during installation. Reset the control board by pressing
OFF and then ENTER, and restart up to two more times if necessary. If unit fails to start, contact a local dealer for
assistance.
7.8 — Electrical Checks
Complete electrical checks as follows:
1. Verify that the generator is OFF. A red LED illuminates to confirm that system is in OFF mode.
2. Switch the recommended disconnect switch (installed at the gen er at or input to th e Alte rn at ive Po wer Ma nage -
ment System) to the OFF (Open) position.
3. Press MANUAL on the control pad. The engine cranks and starts.
4. Once the generator is running, IMMEDIATELY move the GENERATOR DISCONNECT Circuit Breaker switch to
the ON (Closed) position. This prevents the speed from ramping down before the load is applied, a condition
which could cause the engine to stall.
5. Connect an accurate AC voltmeter and a frequency meter across the output te rminals of the generator. Voltage
should be 220-242 VAC (depending on load) at a frequency of 59.5-60.5 Hertz. If it’s not, verify that the MLCB is
closed and verify AC output and frequency (Hertz or Hz) at the MLCB.
6. Connect the AC voltmeter test leads across neutral and each output leg of the generator in turn. In both cases,
voltage reading should be 110-121 VAC. If it’s not, verify that the MLCB is closed and verify AC output between
the E1 and E2 of the MLCB and Neutral at the generator . Also, verify wiring from generator to the electrical loads
that are to be powered by the generator.
7. Move the Generator Disconnect Circuit Breaker switch to the OFF (Open) position.
8. Press OFF on the control pad to shut down the engine.
NOTE: It is important not to proceed until certain that generator AC voltage and frequency are correct and
within the stated limits.
The secondary 12V DC fan continues to operate for up to one hour af ter 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.
7.9 — Generator Tests Under Load
1. Test the generator with electrical loads applied. S t art b y placin g all of the breakers on the Alternative Power Man-
agement System into the OFF (Open) position.
2. Switch the recommended disconnect switch installed at the generator input to the Alternative Power Manage-
ment System to OFF (Open) position.
3. Place the main Circuit Breaker on the generator in the ON (Closed) position.
4. Press MANUAL on the control pad. The generator should crank and start immediately. Allow the engine to stabi-
lize and warm up for a few minutes.
5. Check voltage and frequency at the disconnect switch installe d between the generator and the Alternative Power
Management System.
36 Installation Guidelines for Air-Cooled Generators
Operation
6. Close the disconnect switch if the appropriate voltage and frequency are present.
7. Check voltage and frequency at the Alternative Power Management System by closing the breakers one at a
time (if applicable).
8. Allow the generator to run under load for 20 -30 minutes while checking for unusual noises, vibr ation or other indi-
cations of abnormal operation, such as oil leaks or overheating.
9. With the generator carrying the entire priority load, check gas pressure to verify that it is at the same level it was
before the generator was started.
10. When completed, open the disconnect switch and allow the generator to run at no load.
11. Press OFF on the control pad. The generator will shut down.
12. Place the disconnect switch to the ON (Closed) position.
7.10 — Checking Automatic Operation
1. Press AUTO on the control pad. The system is now ready for automatic operation.
2. Verify that the remote two-wire start test switch installed near the Alternative Power Management System is set
to the ON (Closed) position. This will cause the generator to start automatically.
3. With the generator running and powering loads, set the remote two- wire st art te st switch to th e OFF (Open) posi-
tion. In approximately one minute the generator will automatically shut down.
7.11 — Installation Summary
1. Ensure that the installation has been properly performed as outlined by the manufacturer and that it meets all
applicable laws and codes.
2. Test and confirm proper operation of the system as outlined in the appropriate installation and owner’s manuals.
3. Educate the end-user on the proper operation, ma intenance and service call procedures.
Installation Guidelines for Air-Cooled Generators 37
Operation
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38 Installation Guidelines for Air-Cooled Generators
Section 8 Troubleshooting
8.1 — Engine Troubleshooting
Table 8-1. Engine Diagnostics
Problem Cause Correction
Engine will not crank. 1) Fuse blown.
2) Loose, corroded or defective battery
cables.
3) Defective starter contact.
4) Defective starter motor.
5) Dead Battery.
Engine cranks but will not
start.
Engine starts hard and runs
rough.
Generator is set to OFF, but
the engine continues to run.
No AC output from generator.
1) Out of fuel.
2) Defective fuel solenoid (FS).
3) Defective spark plug(s).
4) Va lve clearance needs adjustment.
1) Air cleaner plugged or damaged.
2) Defective spark plug(s).
3) Fuel regulator not set.
4) Fuel pressure incorrect.
5) Fuel selector in wrong position.
1) Control board wired incorrectly.
2) Defective control board.
1) Main line circuit breaker is in the OFF
(or OPEN) position.
2) Generator internal failure.
1) Correct short circuit condition by
replacing 7.5 Amp fuse.
2) Tighten, clean or replace as necessary.*
3) Tighten, clean or replace as necessary.*
4) Tighten, clean or replace as necessary.*
5) Charge or replace battery.
1) Replenish fuel / Turn on fuel valve.
2) *
3) Clean, re-gap or replace plug(s).
4) Adjust valve clearance.
1) Check / replace air cleaner.
2) Clean, re-gap or replace plug(s).
3) Set fuel regulator.
4) Confirm fuel pressure to regulator is 10-
12” water column (19-22mm mercury)
for LP, and 3.5 - 7” water column (913mm mercury) for natural gas.
5) Move selector to correct position.
1) Repair wiring or replace control board.*
2) Replace control board.
1) Reset circuit breaker to ON (or
CLOSED).
2) *
Unit consumes large
amounts of oil.
* Contact an Authorized Independent Service Dealer for assistance.
Installation Guidelines for Air-Cooled Generators 39
1) Oil tank is over filled with oil.
2) Engine breather defective.
3) Improper type or viscosity of oil.
4) Damaged gasket, seal or hose.
1) Adjust oil to proper level.
2) *
3) See “Engine Oil Recommendations.”
4) Check for oil leaks.
Troubleshooting
8.2 — Generator Troubleshooting
Table 8-2. Generator Diagnostics
Active Alarm LED Problem
NONE GREEN Unit running in AUTO but no
power in house.
HIGH
TEMPERATURE
OVERLOAD
REMOVE LOAD
RPM SENSE
LOSS
NOT
ACTIVATED
None GREEN Unit will not start in AUTO with 2-
LOW OIL
PRESSURE
RPM SENSE
LOSS
OVERCRANK RED Unit will not start in AUTO with 2-
LOW VOLTS
REMOVE LOAD
FUSE PROBLEM
OVERSPEED RED Unit will not start in AUTO with 2-
UNDER
VOLTAGE
UNDERSPEED RED Unit will not start in AUTO with 2-
RED Unit shuts down during operation. Check the
RED Unit shuts down during operation. Check the
RED Unit was running and shuts down,
attempts to restart.
NONE Unit will not start in AUTO with 2-
wire start signal.
wire start signal.
RED Unit will not start in AUTO with 2-
wire start signal.
RED Unit will not start in AUTO with 2-
wire start signal.
wire start signal.
RED Unit will not start in AUTO with 2-
wire start signal.
RED Unit will not start in AUTO with 2-
wire start signal.
wire start signal.
RED Unit will not start in AUTO with 2-
wire start signal.
wire start signal.
Things to
Check
Check Generator Disconnect circuit
breaker.
LEDs/Screen
for alarms.
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
See if screen
says unit not
activated.
Check screen
for start delay
countdown.
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
Solution
Contact servicing dealer if Generator
Disconnect circuit breaker is in the ON
position.
Check ventilation around the intake,
exhaust and rear of generator. Contact
serving dealer if no obstruction is found.
Clear alarm and remove household
loads from the generator. Put back in
AUTO and restart.
Clear alarm and remove household
loads from the generator. Put back in
AUTO and restart. If problem returns,
contact servicing dealer to investigate
possible fuel issue.
Refer to activation section in Owner’s
Manual.
If the start up delay is greater than
expected, contact servicing de a l er to
adjust from 2 to 1500 seconds.
Check oil level. Add oil per Owner’s
Manual. Contact servicing dealer if oil
level is correct.
Clear alarm. Navigate to the BATTERY
MENU on the control pad LCD. Contact
servicing dealer if battery is GOOD.
Replace battery If CHECK BATTERY is
displayed.
Check fuel line shutoff valve is in the ON
position. Clear alarm. Attempt to start
the unit in MANUAL. If it does not start
or starts and runs rough, contact servicing dealer.
Clear alarm and remove household
loads from the generator. Set back to
AUTO and restart.
Check ATO 7.5 Amp fuse . Replace with
same type fuse if bad. Contact servicing
dealer if fuse is good.
Contact servicing dealer.
Contact servicing dealer.
Contact servicing dealer.
40 Installation Guidelines for Air-Cooled Generators
Table 8-2. Generator Diagnostics (Continued)
Troubleshooting
Active Alarm LED Problem
STEPPER
OVERCURRENT
MISWIRE RED Unit will not start in AUTO with 2-
OVERVOLTAGE RED Unit will not start in AUTO with 2-
LOW BATTERY YELLOW Yellow LED illuminate d in any
BATTERY
PROBLEM
CHARGER
WARNING
SERVICE A YELLOW Yellow LED illuminated in any
SERVICE B YELLOW Yellow LED illuminated in any
Inspect Battery YELLOW Yellow LED illuminated in any
RED Unit will not start in AUTO with 2-
wire start signal.
wire start signal.
wire start signal.
state.
YELLOW Yellow LED illuminated in any
state.
YELLOW Yellow LED illuminated in any
state.
state.
state.
state.
Things to
Check
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
Check screen
for additional
information.
Check screen
for additional
information.
Check screen
for additional
information.
Check screen
for additional
information.
Check screen
for additional
information.
Check screen
for additional
information.
Solution
Contact servicing dealer.
Contact servicing dealer.
Contact servicing dealer.
Clear alarm. Navigate to the BATTERY
MENU on the control pad LCD. Contact
servicing dealer if battery is GOOD.
Replace battery If CHECK BATTERY is
displayed.
Contact servicing dealer.
Contact servicing dealer
Perform SCHEDULE A maintenance.
Press ENTER to clear.
Perform SCHEDULE B maintenance.
Press ENTER to clear.
Inspect battery. Press ENTER to clear.
Installation Guidelines for Air-Cooled Generators 41
Troubleshooting
8.3 — G-Flex™ Troubleshooting
Table 8-3. G-Flex™ Diagnostics
Ecode/Active
Alarm
1048 VSCF Overload RED Unit shuts down
1049 VSCF Overload RED Unit shuts down
1051 VSCF High
Battery
1052 VSCF DC
Overvoltage
1053 VSCF Gate
Fault
1054 VSCF IGBT
Overtemp.
1055 VSCF Phase
Error
1056 VSCF
Undervoltage
LED Problem
during operation.
during operation.
YELLOW Yellow LED illumi-
nated 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.
Things to
Check
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
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 (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 AV R 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. Contac t servicing dealer.
42 Installation Guidelines for Air-Cooled Generators
Table 8-3. G-Flex™ Diagnostics (Continued)
Troubleshooting
Ecode/Active
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
LED Problem
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.
during operation.
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
one hour to cool
electronics with-
out fan.
Things to
Check
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
Check the
LEDs/Screen
for alarms.
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 fi lter faulty. Replace AVR filter.
2) Intake or exhaust air path is blocked. Check intake and
exhaust.
3) The BIG fan is not running (only runs when the engine
is running). KEEP FINGERS AWAY FROM FAN HOUS-
ING- PERSONAL INJURY CAN OCCUR IF FAN IS RUNNING. Contact servicing dealer.
4) Air leak in AVR en closure. Contact servi c ing 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 60 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.
Installation Guidelines for Air-Cooled Generators 43
Troubleshooting
Symptom Possible Causes
Table 8-4. G-Flex™ Diagnostics (Continued)
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.
44 Installation Guidelines for Air-Cooled Generators
Section 9 Accessories
9.1 — Descriptions
NOTE: Contact an independent Authorized Dealer for additional information on accessories.
Table 9-1. Accessories
Accessory Description
Cold Weather Kit Required in areas where temperat ures regularly fall below 32 º F (0 º C).
Scheduled Maintenance Kit Includes all pieces necessary to perform maintenance on the generator along with oil recom-
mendations.
Mobile Link™ Provides a personalized web portal that displays the generator’s status, maintenance schedule,
event history and much more. This portal is accessible via computer, tablet or smart phone.
Sends emails and/or text notifications the moment there is any change in the generator’s status. Notification settings can be customized to what type of alert is sent and how often. For
more information, visit www.standbystatus.com.
Wireless Local Monitor Completely wireless and battery powered, the Wireless Local Monitor provides you with instant
status 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
foot line of sight communication.
Touch-Up Paint Kit Very important to maintain the look and integrity of the generator enclosure. This kit includes
touch-up paint and instructions.
Installation Guidelines for Air-Cooled Generators 45
Accessories
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46 Installation Guidelines for Air-Cooled Generators
Section 10 Installation Diagrams
914 [36.0]
MINIMUM OPEN AREA
ON SIDES AND FRONT
457.2
[18.0]
76.2 [3.0]
PEA GRAVEL
MINIMUM
1229.5
[48.4]
1226
[48.3]
637.6
[25.1]
642
[25.3]
300.4
[11.8]
179.0
[7.0]
560.0
[22.0]
353.7
[13.9]
1154.0
[45.4]
446.6
[17.6]
389.7
[15.3]
36.0
[1.4]
44.8
[1.8]
LEFT SIDE VIEW
REAR VIEW
"DO NOT LIFT BY ROOF"
**ALL DIMENSIONS IN:
MILLIMETERS [INCHES]
A CONCRETE PAD
OPTIONAL MOUNTING TO
HOLE LOCATIONS FOR
TOP VIEW
16.0 [5/8] DIA. CLEARANCE
HOLE (2) PLACES,
3/8 DIA. MASONRY ANCHOR
BOLTS RECOMMENDED
AIR INTAKE
AIR OUTLET
AIR INTAKE
FUEL INLET - 15KW (1/2" NPT)
REQUIRED FUEL PRESSURE: NATURAL GAS : 3.5-7" WATER COLUMN
LIQUID PROPANE (VAPOR) : 10-12" WATER COLUMN
GROUND LUG
GROUND STUD
CABLE ACCESS HOLE
FRONT VIEW
RIGHT SIDE VIEW
FRONT OF UNIT
10.0 [3/8] DIA. CLEARANCE
HOLE (2) PLACES,
3/8 DIA. MASONRY ANCHOR
BOLTS RECOMMENDED
A CONCRETE PAD
OPTIONAL MOUNTING TO
HOLE LOCATIONS FOR
30.2 [ 1.2]
LIFTING HOLES 4 CORNERS
10.1 — Installation Drawing
Installation Guidelines for Air-Cooled Generators 47
Installation Diagrams
HOUSE
LOADS*
ENGINE
CONTROLLER
VOLTAGE
REGULATOR
(AVR)
ENGINE
START
BATTERY
CHARGER
12 VOLT
ENGINE
START
BATTERY
ALTERNATOR
BATTERY
CHARGER
INVERTER
TWO-WIRE
START
BATTERY
VOLTAGE
SENSING
AC
DISTRIBUTION
PANEL
120/240V
DC
DISTRIBUTION
PANEL
12V/24V/48V
BATTERY
12V/24V/48V
INVERTER/CHARGER
*House Loads must be less than 10 kW or 2 hp
GENERATOR
HOUSE
HOUSE
LOADS*
120V/240V
CHARGER
SUPPLY
TWO-WIRE
START
TWO-WIRE
START
24/48V
DC
12/24/36/48V
DC
WIND
TURBINE
PHOTO
VOLTAIC
PANEL
120/240V
OUTPUT
ECOGEN - TYPICAL OFF-GRID APPLICATION SYSTEM
DIAGRAM
10.2 — Off Grid Mode Application Schematic
48 Installation Guidelines for Air-Cooled Generators
10.3 — Oil Make Up System Schematic
SCHEMATIC
(NOT TO SCALE)
VENT HOSE
ENGINE-IN HOSE
(TO OIL PUMP)
COOLER-IN HOSE
HOSE
COOLER-OUT
Installation Diagrams
OIL MAKE UP SYSTEM
ENGINE-OUT HOSE
OIL DIPSTICK AND FILL
Installation Guidelines for Air-Cooled Generators 49
Installation Diagrams
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50 Installation Guidelines for Air-Cooled Generators
Part No. 0K6047 Rev. B 09/08/2014 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.com
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