Generac Power Systems EcoGen G0061030 Bedienungsanleitung

Owner’s Manual

60 Hz Air-Cooled Generators

15 kW EcoGen™

SAVE THIS MANUAL FOR FUTURE REFERENCE

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000918

WWW.GENERAC.COM

1-888-GENERAC

(888-436-3722)

(000209a)

WARNING

This product is not intended to be used in

a critical life support application. Failure to

adhere to this warning could result in

death or serious injury.

ii Owner’s Manual for 60 Hz Air-cooled Generators

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

Record the information found on your unit data label on this

page. For the location of the unit data label, see Component

Locations. The unit has a label plate affixed to the inside

partition, to the left of the control panel console as shown in

Component Locations For directions on how to open the

top lid and remove the front panel, see Operation.

When contacting an Independent Authorized Service Dealer

about parts and service, always supply the complete model

number and serial number of the unit.

Operation and Maintenance: Proper maintenance and care

of the generator ensures a minimum number of problems

and keeps operating expenses at a minimum. It is the

operator’s responsibility to perform all safety checks, to

make sure that all maintenance for safe operation is

performed promptly, and to have the equipment checked

periodically by an Independent Authorized Service Dealer.

Normal maintenance, service and replacement of parts are

the responsibility of the owner/operator and, as such, are not

considered defects in materials or workmanship within the

terms of the warranty. Individual operating habits and usage

may contribute to the need for additional maintenance or

service.

When the generator requires servicing or repairs, Generac

recommends contacting an Independent Authorized Service

Dealer for assistance. Authorized service technicians are

factory-trained and are capable of handling all service

needs.To locate the nearest Independent Authorized Service

Dealer, please visit the dealer locator at:

www.generac.com/Service/DealerLocator/.

Model:

Serial:

Prod Date Week:

Volts:

LPV Amps:

NG Amps:

Hz:

Phase:

Controller P/N:

(000005)

WARNING

California Proposition 65. This product contains or

emits chemicals known to the state of California to

cause cancer, birth defects, and other reproductive

harm.

(000004)

WARNING

California Proposition 65. Engine exhaust and some

of its constituents are known to the state of California

to cause cancer, birth defects, and other reproductive

harm.

Owner’s Manual for 60 Hz EcoGen™ Generator iii

Section 1: Safety Rules & General

Information

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

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

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

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

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

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

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

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

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

Section 2: General Information

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Section 3: Operation

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

Side Compartment .............................................11

Main Circuit Breaker (Generator Disconnect) ............11

LED Indicator Lights ..................................................11

120V GFCI Outlet/15 Amp Breaker ...........................11

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

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

Using the Auto/Off/Manual Interface Menu ....13

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

Change Time and Date ...................................... 14

Programmable Timers ...................................... 14

Dealer Programmable ...............................................14

High Run Speed Timer ...................................................14

USB Port for Firmware Updates ....................... 14

Battery Charger ................................................. 17

Manual Transfer Operation ............................... 17

Transfer to Generator Power Source ........................17

Transfer Back to Utility Power Source .......................17

Automatic Transfer Operation ......................... 18

Automatic Sequence of Operation .................. 18

Utility Failure ..............................................................18

Cranking ....................................................................18

Cold Smart Start ........................................................18

Load Transfer ............................................................18

Shutting Generator Down While Under Load . 18

To turn the generator OFF: .......................................18

To turn the generator ON: .........................................18

Section 4: Maintenance

Performing Scheduled Maintenance ............... 19

Check Enclosure Louvers ................................ 20

Check Lines and Connections ......................... 20

Checking Engine Oil Level ............................... 21

Engine Oil Recommendations ...................................21

Changing the Oil and Oil Filter ......................... 22

EcoGen Oil System Drain Pump Kit Parts List ..........22

EcoGen Oil System Drain Pump Assembly ..............22

EcoGen Oil Change Procedure .................................23

Replacing the Engine Air Filter ........................ 24

Replacing the AVR Filter .................................. 24

Maintaining the Spark Plugs ............................ 25

Valve Clearance Adjustment ............................ 25

Check Valve Clearance .............................................25

Adjust Valve Clearance .............................................25

Battery Maintenance ......................................... 26

Attention After Submersion ............................. 27

Corrosion Protection ........................................ 27

Table of Contents

Section 1:

iv Owner’s Manual for 60 Hz EcoGen™ Generator

Remove From / To Service Procedure .............27

Remove From Service .............................................. 27

Return to Service ...................................................... 27

Section 5: Troubleshooting / Diagnostics

Engine Troubleshooting ...................................29

Generator Troubleshooting ..............................30

G-Flex™ Troubleshooting .................................32

G-Flex™ Diagnostics .........................................34

Section 6: Installation Diagrams

Installation Drawing............................................35

Off Grid Mode Application Schematic .............36

Oil Make Up System Schematic .......................37

Safety Rules & General Information

Owner’s Manual for 60 Hz EcoGen™ Generator 1

Section 1: Safety Rules & General Information

Introduction

Thank you for purchasing this compact, high

performance, air-cooled, engine-driven generator. It is

designed to automatically supply electrical power to

operate critical loads during a normal power source

failure.

As supplied from the factory, this generator is designed to

work in off-grid applications.

In off-grid applications as a part of an alternative energy

system, the generator starts when the inverter/battery

charger detects the normal power source voltage has

dropped below a preset level. The generator powers the

inverter, and once the voltage level of the normal power

source rises to an acceptable level, the generator is shut

down. Another off-grid application would be for use in

remote locations such as for pumping water for a village

or campground, or for livestock.

The unit is factory installed in an all-weather metal

enclosure and is intended for outdoor installation only.

The generator can be operated using either natural gas

(NG) or vapor withdrawn liquid propane (LP).

NOTE: When sized properly, this generator is suitable for

supplying typical residential loads such as induction

motors (sump pumps, refrigerators, air conditioners,

furnaces, etc.), electronic components (computer,

monitor, TV, etc.), lighting loads and microwaves.

Read This Manual Thoroughly

If any portion of this manual is not understood, contact

the nearest Independent Authorized Service Dealer for

starting, operating and servicing procedures.

This manual must be used in conjunction with the

appropriate Installation Manual.

SAVE THESE INSTRUCTIONS: The manufacturer

suggests that this manual and the rules for safe operation

be copied and posted near the unit installation site.

Safety should be stressed to all operators and potential

operators of this equipment.

Throughout this publication and on tags and decals

affixed to the generator, DANGER, WARNING, and

CAUTION blocks are used to alert personnel to special

instructions about a particular operation that may be

hazardous if performed incorrectly or carelessly. Observe

them carefully. Their definitions are as follows:

NOTE: Notes provide additional information important to

a procedure or component.

These safety warnings cannot eliminate the hazards they

indicate. Observing safety precautions and strict

compliance with the special instructions while performing

the action or service are essential to preventing accidents.

The operator is responsible for proper and safe use of

the equipment. The manufacturer strongly recommends

that if the operator is also the owner, to read the Owner’s

Manual and thoroughly understand all instructions before

using this equipment. The manufacturer also strongly

recommends instructing other users to properly start and

operate the unit. This prepares them if they need to

operate the equipment in an emergency.

How to Obtain Service

When the generator requires servicing or repairs, contact

an Independent Authorized Service Dealer for assistance.

Service technicians are factory-trained and are capable of

handling all service needs. For assistance locating a

dealer, go to

www.generac.com/Service/DealerLocator/.

When contacting a dealer about parts and service,

always supply the complete model number and serial

number of the unit as given on its data decal, which is

located on the generator. Refer to Figure 2-1 for decal

location. Record the model number and serial numbers in

the spaces provided on the inside front cover of this

manual.

(000100a)

WARNING

Consult Manual. Read and understand manual

completely before using product. Failure to

completely understand manual and product

could result in death or serious injury.

(000001)

DANGER

Indicates a hazardous situation which, if not avoided,

will result in death or serious injury.

(000002)

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

(000003)

CAUTION

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate injury.

Safety Rules & General Information

2Owner’s Manual for 60 Hz EcoGen™ Generator

Safety Rules

Study these SAFETY RULES carefully before installing,

operating or servicing this equipment. Become familiar

with this Owner’s Manual and with the unit. The

generator can operate safely, efficiently and reliably only

if it is properly installed, operated and maintained. Many

accidents are caused by failing to follow simple and

fundamental rules or precautions.

The manufacturer cannot anticipate every possible

circumstance that might involve a hazard. The warnings in

this manual and on tags and decals affixed to the unit are,

therefore, not all-inclusive. If using a procedure, work

method, or operating technique the manufacturer does not

specifically recommend, verify that it is safe for others.

Also, make sure the procedure, work method or operating

technique utilized does not render the generator unsafe.

General Hazards

(000190)

DANGER

Loss of life. Property damage. Installation must always

comply with applicable codes, standards, laws and

regulations. Failure to do so will result in death

or serious injury.

Automatic start-up. Disconnect normal power source

and render unit inoperable before working on unit.

Failure to do so will result in death or serious injury.

(000236)

DANGER

(000209a)

WARNING

This product is not intended to be used in

a critical life support application. Failure to

adhere to this warning could result in

death or serious injury.

WARNING

This unit is not intended for use as a prime power

source. It is intended for use as an intermediate power

supply in the event of temporary power outage only.

See individual unit specifications for required

maintenance and run times pertaining to use. (000247)

(000187)

WARNING

(000130)

WARNING

Accidental Start-up. Disconnect the negative battery

cable, then the positive battery cable when working

on unit. Failure to do so could result in death

or serious injury.

(000182)

WARNING

(000155)

WARNING

Only a trained and licensed electrician should perform

wiring and connections to unit. Failure to follow proper

installation requirements could result in death, serious

injury, and damage to equipment or property.

(000115)

WARNING

Moving Parts. Do not wear jewelry when

starting or operating this product. Wearing

jewelry while starting or operating this product

could result in death or serious injury.

(000111)

WARNING

Moving Parts. Keep clothing, hair, and

appendages away from moving parts. Failure

to do so could result in death or serious injury.

(000108)

WARNING

Hot Surfaces. When operating machine, do not

touch hot surfaces. Keep machine away from

combustibles during use. Hot surfaces

could result in severe burns or fire.

WARNING

Injury and equipment damage. Do not use

generator as a step. Doing so could result in falling,

damaged parts, unsafe equipment operation,

and could result in death or serious injury. (000216)

(000146)

WARNING

Equipment and property damage. Do not alter

construction of, installation, or block ventilation for

generator. Failure to do so could result in unsafe

operation or damage to the generator.

Safety Rules & General Information

Owner’s Manual for 60 Hz EcoGen™ Generator 3

Inspect the generator regularly, and contact the nearest

Independent Authorized Service Dealer for parts needing

repair or replacement.

Exhaust Hazards

•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 provisions, as

this can seriously affect safe operation of the

generator. The generator must be installed and

operated outdoors only.

Electrical Hazards

WARNING

Risk of injury. Do not operate or service this

machine if not fully alert. Fatigue can impair the

ability to service this equipment and could result

in death or serious injury. (000215)

WARNING

Environmental Hazard. Always recycle batteries at an

official recycling center in accordance with all local

laws and regulations. Failure to do so could result in

environmental damage, death or serious injury.

(000228)

Asphyxiation. Running engines produce

carbon monoxide, a colorless, odorless,

poisonous gas. Carbon monoxide, if not

avoided, will result in death or serious injury.

(000103)

DANGER

(000178a)

Asphyxiation. Always use a battery operated carbon

monoxide alarm indoors and installed according to

the manufacturer’s instructions. Failure to do so

could result in death or serious injury.

WARNING

(000144)

DANGER

Electrocution. Contact with bare wires,

terminals, and connections while generator

is running will result in death or serious injury.

(000150)

DANGER

Electrocution. Never connect this unit to the electrical

system of any building unless a licensed electrician

has installed an approved transfer switch. Failure to

do so will result in death or serious injury.

(000237)

DANGER

Electrical backfeed. Use only approved switchgear to

isolate generator from the normal power source.

Failure to do so will result in death, serious injury,

and equipment damage.

(000152)

DANGER

Electrocution. Verify electrical system is

properly grounded before applying power.

Failure to do so will result in death or serious

injury.

(000188)

DANGER

Electrocution. Do not wear jewelry while

working on this equipment. Doing so will

result in death or serious injury.

(000104)

DANGER

Electrocution. Water contact with a power

source, if not avoided, will result in death

or serious injury.

(000144)

DANGER

Electrocution. Contact with bare wires,

terminals, and connections while generator

is running will result in death or serious injury.

(000145)

DANGER

Electrocution. In the event of electrical accident,

immediately shut power OFF. Use non-conductive

implements to free victim from live conductor. Apply

first aid and get medical help. Failure to do so will

result in death or serious injury.

Safety Rules & General Information

4Owner’s Manual for 60 Hz EcoGen™ Generator

Fire Hazards

Comply with regulations the Occupational Safety and

Health Administration (OSHA) has established. Also,

verify that the generator is installed in accordance with

the manufacturer’s instructions and recommendations.

Following proper installation, do nothing that might alter a

safe installation and render the unit in noncompliance

with the aforementioned codes, standards, laws and

regulations.

Explosion Hazards

WARNING

Fire hazard. Do not obstruct cooling and

ventilating airflow around the generator. Inadequate

ventilation could result in fire hazard, possible

equipment damage, death or serious injury. (000217)

WARNING

Fire and explosion. Installation must comply

with all local, state, and national electrical

(000218)

building codes. Noncompliance could result in unsafe

operation, equipment damage, death or serious injury.

WARNING

Fire hazard. Use only fully-charged fire

(000219)

extinguishers rated “ABC” by the NFPA. Discharged or

improperly rated fire extinguishers will not extinguish

electrical fires in automatic standby generators.

(000100a)

WARNING

Consult Manual. Read and understand manual

completely before using product. Failure to

completely understand manual and product

could result in death or serious injury.

WARNING

required safety equipment could result in

death or serious injury. (000221)

Risk of electrocution. Refer to NFPA 70E for

safety equipment required when working with

with a live electrical system. Failure to use

(000147)

WARNING

Risk of Fire. Unit must be positioned in a

manner that prevents combustible material

accumulation underneath. Failure to do so

could result in death or serious injury.

(000192)

DANGER

(000151)

DANGER

Connection of fuel source must be done by a qualified

professional technician or contractor. Incorrect installation

of this unit will result in death, serious injury, and damage

to equipment and property damage.

(000174)

DANGER

Risk of fire. Allow fuel spills to completely dry

before starting engine. Failure to do so will

result in death or serious injury.

(000110)

WARNING

Risk of Fire. Hot surfaces could ignite

combustibles, resulting in fire. Fire could

result in death or serious injury.

General Information

Owner’s Manual for 60 Hz EcoGen™ Generator 5

Section 2: General Information

EcoGen Operating Principle

Benefits

The 15 kW EcoGen generator brings exciting new

technology to the Home Standby generator product. The

generator is significantly more fuel-efficient than constant

speed generators at normal loads, provides premium

power quality, and is significantly quieter while operating

at normal loads.

•Quieter operation - 3 dB with improved tonal qualities

under normal loads

•Cleanest Standby power available with 1.5% THD

•Significant fuel savings: more fuel efficient under

normal loads

•Lower operating speed of 2700 rpm at low loads

•Tuned exhaust system to further lower sound levels

•Variable Speed / Constant Frequency operation

How It Works

In an off-grid solution, the generator is an important

source of backup power when other resources are

insufficient for the demand, improving overall system

reliability.

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

DC current.

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

the battery bank.

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

converts it to AC, and then sends the current to the

AC electrical panel.

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

bank level drops below a preset threshold, the

inverter automatically signals the generator to start.

5. The generator feeds AC power to the inverter,

which in turn sends power to the electric panel and

recharges the battery bank to an acceptable level.

Startup

When the generator starts, the engine speed gradually

increases to 3600 RPM to produce maximum power. This

ensures that there is sufficient power to carry the load on

start-up. The engine RPM then gradually decreases to a

speed appropriate for the attached load.

For example, if there is no load, the engine speed

decreases to approximately 2700 RPM. The time it takes

to decrease to 2700 RPM is approximately 4–5 minutes.

Since the ramp rate is linear, less time would be required

for it to decrease to only 3400 RPM.

During startup, as the engine speed increases to 3600

RPM, the Automatic Voltage Regulator (AVR) electronics

perform a self test involving an overall system check of

the unit. If a fault is detected, the unit shuts down and

displays an alarm.

Normal Running

The engine operates between 2700 RPM–3600 RPM

depending on the attached load. When the load

increases or decreases, the speed increases or

decreases accordingly.

Small Load Changes

The system is designed to maintain the current engine

speed for small load changes. Larger load changes result

in a change in engine speed to appropriately handle the

load.

Large Load (Not Overload)

The engine always runs at a speed appropriate for the

attached load. Typical loads up to 10 kW or 2 hp can be

wired directly. The engine speed remains at 3600 RPM

for a programmable time (20 minutes default) and then

decreases to the speed appropriate for the attached load.

The programmable time can be changed by the dealer to

prevent annoying increases and decreases in engine

speed if large loads turn on and off frequently.

If natural gas is the selected fuel type, then all loads up to

9 kW can be wired directly.

Automatic Voltage Regulator (AVR) Cooling Fans

The system is equipped with two fans to cool the AVR

electronics. The primary fan is powered by AC during

operation. The secondary fan is powered by 12V DC

through the controller. The fans are monitored during

operation and if a failure occurs, an alarm is displayed.

The secondary fan continues to operate for up to one

hour after the generator is shut down. Proper cooling

must occur before removing battery connections for

maintenance or other service activity.

NOTE: The AVR cooling air inlet includes a filter. Verify

the filter is installed and properly seated at time the unit is

installed. Check the filter at regular maintenance intervals

to verify proper airflow.

(000111)

WARNING

Moving Parts. Keep clothing, hair, and

appendages away from moving parts. Failure

to do so could result in death or serious injury.

General Information

6Owner’s Manual for 60 Hz EcoGen™ Generator

The Generator

Figure 2-1. Component Locations

A. Exhaust Enclosure E Data Label I. Fuel Regulator M. Oil Dipstick

B. Automatic Voltage

Regulator (AVR)

F. Control Pad J. Battery Compartment N. Composite Base

C. Engine Air Filter G. Circuit Breakers K. Oil Filter

D. AVR Air Filter H. Fuel Inlet (Back) L. Oil Tank

001380

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