Owner’s Manual 60 Hz Air-Cooled Generators 15 kW EcoGen™ 000918 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. (000209a) Register your Generac product at: WWW.GENERAC.COM 1-888-GENERAC (888-436-3722) Para español, visita: http://www.generac.com/service-support/product-support-lookup Pour le français, visiter : http://www.generac.
Use this page to record important information about your generator set. Model: Serial: Prod Date Week: Volts: LPV Amps: NG Amps: Hz: Phase: Controller P/N: Record the information found on your unit data label on this page. See General Information for the location of the unit data label. The unit has a label plate affixed to the inside partition, to the left of the control panel console as shown in Figure 2-1. See Operation for directions on how to open the top lid and remove the front panel.
Table of Contents Section 1: Safety Rules & General Information Intake Side Panel Removal .......................................12 Introduction ..........................................................1 LED Indicator Lights ..................................................12 Read This Manual Thoroughly ....................................1 Control Panel Interface ..................................... 13 Safety Alerts .........................................................
Table of Contents Corrosion Protection .........................................32 Remove From, and Return To Service Procedure .............................................32 Remove From Service .............................................. 32 Return to Service ...................................................... 32 Section 5: Troubleshooting / Quick Reference Guide Generator Troubleshooting ..............................35 Quick Reference Guide .....................................
Safety Rules & General Information Section 1: Safety Rules & General Information Introduction Safety Alerts 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.
Safety Rules & General Information located on the generator. See Figure 2-1 for decal location. Record the model and serial numbers in the spaces provided on the inside front cover of this manual. Safety Rules Study these SAFETY RULES carefully before installing, operating, or servicing this equipment. Become familiar with this owner’s manual and with the unit. The generator can operate safely, efficiently, and reliably only if it is properly installed, operated, and maintained.
Safety Rules & General Information 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) DANGER Electrocution.
Safety Rules & General Information Fire Hazards Explosion Hazards DANGER 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) (000192) DANGER WARNING Fire and explosion. Installation must comply with all local, state, and national electrical building codes. Noncompliance could result in unsafe operation, equipment damage, death or serious injury.
General Information 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.
General Information The Generator C B G D A E F M K J L R H Q R P O N 003603 Figure 2-1. Components and Control Locations A. AVR E. Control Panel J. Oil Tank N. Sediment Trap B. AVR Filter F. Battery Compartment (Battery not supplied) K. Oil Fill Cap/Oil dip stick O. Fuel Regulator C. Main Line Circuit Breaker (Generator Disconnect) G. Exhaust Enclosure L. Oil Filter P. Fuel Inlet Q. Data Plate Location Airbox with Air Cleaner H. R. Lock with Cover D.
General Information Specifications Generator Model 15 kW EcoGen Rated Voltage 240 Rated Maximum Load Current (Amps) at 240 Volts (LP and NG)* 62.5 Main Circuit Breaker 70 Amp Phase 1 Rated AC Frequency 60 Hz Battery Requirement 12 Volts, Group 26R 540 CCA Minimum or Group 35AGM 650 CCA Minimum Unit Weight in Lbs. (kilos) 471 (213.
General Information Protection Systems The generator may need to run for long periods of time with no operator present to monitor the engine/generator conditions. The generator is equipped with protection systems to automatically shut down the unit to protect against potentially damaging conditions.
General Information Activating the Generator The generator should be activated upon initial start-up. See the installation manual for complete instructions. Replacement Parts Description 15 kW EcoGen 26R Exide Battery 0H34215 Spark Plug 0G0767A Oil Filter 070185E Air Filter 0J8478 Control Panel Fuse 0D7178T AVR Air filter 0K3054 Rotor Brushes 0J8318 Accessories NOTE: Performance enhancing accessories are available for air-cooled generators. Contact an IASD or visit www.generac.
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Operation Section 3: Operation Site Prep Verification 1. Cut the plastic bag to remove the keys. 2. Use the keys to open the lid of the generator. The generator must be installed so that airflow into and out of the generator is not impeded. Verify that all shrubs or tall grasses within 3 ft (0.91 m) of the intake and discharge louvers on the sides of the enclosure have been removed. Install the generator on high ground where water levels will not rise and endanger it.
Operation Intake Side Panel Removal 3. Lift the intake panel up and away from the generator. See Figure 3-2. The intake side panel (A) must be removed to access the battery compartment, fuel regulator, and sediment trap. NOTE: Always lift the intake side panel straight up before pulling away from enclosure. Do not pull the panel away from the enclosure before lifting up (D). 1. Raise the lid and remove the front panel. 2.
Operation Control Panel Interface See Figure 3-5. The control panel interface (A) is located under the lid of the enclosure. Verify that both the left and right side locks are unlocked before attempting to lift the lid of the enclosure. Open the lid as directed in Opening the Lid. Using the AUTO/OFF/MANUAL Interface Button Description of Operation AUTO This button activates fully automatic system operation.
Operation Menu System Navigation To get to the MENU, use the ESCAPE button from any page. You may need to press the ESCAPE button several times before reaching the MENU page. Navigate to the desired menu by using the ↑/↓ buttons. When the desired menu is displayed and flashing, press the ENTER button.
Operation Current Date/Time UP ARROW = 02/14/13 07:40 + ESC ENTER DOWN ARROW = Run Hours (H) - 0.0 ENTER ESC ESC MAINT : ESC MAINT ENTER Run Hrs Maint.
Operation Battery Charger • output NOTE: The battery charger is integrated into the control module in all models. • charging levels are safe. The battery charger operates as a smart charger that verifies: MANUAL is continually maximum battery life. optimized to promote NOTE: A warning is displayed on the LCD when the battery needs service. • Will not transfer to generator if MLCB (generator disconnect) is OFF (OPEN). • Will transfer to generator if MLCB (generator disconnect) is ON (CLOSED).
Maintenance Section 4: Maintenance Maintenance Regular maintenance will improve performance and extend engine/equipment life. Generac Power Systems, Inc. recommends that all maintenance work be performed by an Independent Authorized Service Dealer (IASD). Regular maintenance, replacement, or repair of the emissions control devices and systems may be performed by any repair shop or person of the owner’s choosing.
Maintenance Service Schedule Service Weekly Check Enclosure Louvers for Dirt and Debris Every Three Months Every Year Schedule A Schedule B Every Every Two Years or 500 Hours Four Years or 1000 Hours Check AVR and Engine Filter Check Lines and Connections for Fuel or Oil Leaks Check Engine Oil Level Check Spark Plugs Check Battery Condition Replace AVR Filter* Replace Engine Oil Filter and Oil in Oil Tank** Replace Engine Air Filter Replace Spark Plugs Adjust Valve
Maintenance Checking Engine Oil Level 2. Allow the generator to start and warm up for a few minutes. WARNING Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury. (000139) WARNING Skin irritation. Avoid prolonged or repeated contact with used motor oil. Used motor oil has been shown to cause skin cancer in laboratory animals. Thoroughly wash exposed areas with soap and water. (000210) CAUTION Engine damage.
Maintenance Changing the Oil and Oil Filter B A E F G C A D B C E F G 001385 Figure 4-3. Exploded View – EcoGen Oil System Drain Pump Kit An Oil System Drain Pump Kit (P/N 0K3717) has been shipped with this unit. Refer to the instructions included with that kit for assembly and use of the Oil System Drain Pump. If the Oil System Drain Pump has become lost, or is unavailable, use a suitable suction pump to perform the following oil change procedure. EcoGen Oil System Drain Pump Assembly 1.
Maintenance EcoGen Oil Change Procedure WARNING Skin irritation. Avoid prolonged or repeated contact with used motor oil. Used motor oil has been shown to cause skin cancer in laboratory animals. Thoroughly wash exposed areas with soap and water. (000210) 1. Place the MLCB to the OFF position. 2. Press the Control Panel MANUAL button to operate the unit. 3. Verify the engine is at operating temperature by operating the unit for a minimum of 20 minutes. 4.
Maintenance 16. Screw the new oil filter on by hand until the filter gasket contacts the oil filter adapter. Tighten the new oil filter ¾ to one full turn more. 17. Refill the oil tank with the proper recommended oil. Do not fill above the full mark on the dipstick. 18. Start the engine, run for one minute and check for leaks. 19. Stop the engine for a minimum of 10 minutes. 20. Recheck the oil level and add oil if necessary. 6. Install the air cleaner cover and cover clip.
Maintenance Maintaining the Spark Plugs 10. Install AVR filter housing. Check and replace the spark plugs as necessary. WARNING Valve Clearance Adjustment Electrical shock. Do not disconnect spark plug wires with engine running. Doing so could result in death or serious injury. (000140) WARNING Moving Parts. Avoid AVR fan housing for 80 minutes after generator shutdown. Fan operates even if fuse is removed. Rotating fan blades could result in death or serious injury.
Maintenance B D E F C 002380 001414 Figure 4-16. Remove AVR Fan Screws 5. Remove spark plug cables from spark plug terminals. 6. Remove spark plugs. 7. Make sure the piston is at top dead center (TDC) of its compression stroke (both valves closed). To move the piston to TDC, remove the intake screen at the front of the engine to access the flywheel nut. Use a large socket and socket wrench to rotate the flywheel nut clockwise, which will rotate the crankshaft.
Maintenance Battery Maintenance The battery should be regularly inspected per the Service Schedule. Contact an IASD for assistance if necessary. WARNING Proceed as follows to inspect the battery: (000137a) 1. Press the OFF button to shut down the generator, then lift the lid and remove the front panel. 2. Remove the 7.5 amp fuse from the control panel. 3. Remove the intake side panel. (See Intake Side Panel Removal.) 4. See Figure 4-1. Disconnect the white battery charger cable.
Maintenance B Remove From, and Return To Service Procedure Remove From Service If the generator will be out of service longer than 90 days, proceed as follows to prepare the generator for storage: 1. Start the engine and let it warm up. 2. Close the fuel shutoff valve in the fuel supply line and allow the engine to stop. A 001821 Figure 4-19. Cleaning the Sediment Trap 4. Use a clean-out tool (not provided) to remove accumulated moisture and particles from the cap and body (B). 5.
Maintenance charge. Replace the battery if it will not maintain a charge. 4. Clean and wipe down the entire generator. 5. Verify that the 7.5 amp fuse is removed from the generator control panel. 6. Reconnect the battery. Observe battery polarity. Damage may occur if the battery is connected incorrectly. Install positive cable first. 7. Reconnect the battery charger AC input T1/Neutral cable (white sleeve) at controller. 8. Open the fuel shutoff valve. 9. Insert the 7.
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Troubleshooting / Quick Reference Guide Section 5: Troubleshooting / Quick Reference Guide Generator Troubleshooting Problem Engine will not crank. Cause 1. Blown fuse. Correction 2. Loose, corroded, or defective battery cables. 3. Defective starter contact. 4. Defective starter motor. 5. Discharged battery. 1. Correct short circuit condition by replacing 7.5 amp fuse in generator control panel. Contact an Independent Authorized Service Dealer (IASD) if fuse continues to blow. 2.
Troubleshooting / Quick Reference Guide Quick Reference Guide To clear an active alarm, press the OFF button, the ENTER button, and then press AUTO. If the alarm reoccurs, contact an IASD. Active Alarm NONE LED Problem Things to Check FLASHING Unit running in AUTO but Check MLCB. GREEN no power at L1 and L2. Solution Check MLCB. If it is ON, contact an IASD. HIGH TEMPERATURE RED Unit shuts down during operation. Check the LEDs / screen for alarms.
Troubleshooting / Quick Reference Guide Active Alarm LED Problem Things to Check Solution UNDERSPEED RED Unit will not start in AUTO with remote start signal. Check the LEDs / screen for alarms. Contact an IASD. STEPPER OVERCURRENT RED Unit will not start in AUTO with remote start signal. Check the LEDs / screen for alarms. Contact an IASD. MISWIRE RED Unit will not start in AUTO with remote start signal. Check the LEDs / screen for alarms. Contact an IASD.
Troubleshooting / Quick Reference Guide AVR Troubleshooting Table 5-1. AVR Troubleshooting Ecode/Active Alarm LED Problem Things to Check Possible Causes/Solution 1048 VSCF Overload RED Unit shuts down during operation. Check the LEDs/Screen for alarms. Alternator, AVR or wiring is damaged. Contact servicing dealer. 1049 VSCF Overload RED Unit shuts down during operation. Check the LEDs/Screen for alarms. Generator output is shorted or severely overloaded.
Troubleshooting / Quick Reference Guide Table 5-1. AVR Troubleshooting Ecode/Active Alarm LED Problem Things to Check Possible Causes/Solution 1057 VSCF Overvoltage RED Unit shuts down during operation or starting. Check the LEDs/Screen for alarms. Probable causes are: 1) The generator has been overloaded. Remove load and attempt to restart unit. 2) Generator has started into a severe load. Manually operate generator breaker and try to restart unit.
Troubleshooting / Quick Reference Guide AVR Diagnostics Table 5-2. AVR Diagnostics Symptom Possible Causes Generator stalls when large load is supplied. Total load is too big for the generator. Loads must be less than 10 kW or 2 hp when operating under 3600 rpm.Contact installing dealer to correct installation. Output voltage is low/high. Voltage calibration incorrect. Contact servicing dealer. Generator does not pull full power. Current calibration incorrect. Contact servicing dealer.
Part No. 0L6633 Rev. A 09/13/16 ©2016 Generac Power Systems, Inc. All rights reserved Specifications are subject to change without notice. No reproduction allowed in any form without prior written consent from Generac Power Systems, Inc. Generac Power Systems, Inc. S45 W29290 Hwy. 59 Waukesha, WI 53189 1-888-GENERAC (1-888-436-3722) generac.
