GENERAC 7179 60 Hz Air-Cooled Generators Installation Guide

7179 60 Hz Air-Cooled Generators

®
Installation Guidelines
60 Hz Air-Cooled Generators
15kW EcoGenTM

WARNING

Loss of life. 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.

(000209b)

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.com/service-support /product-support-lookup

SAVE THIS MANUAL FOR FUTURE REFERENCE

Use this page to record important information about this generator.

Model: Serial: Production Date: Volts: LPV Amps: NG Amps: Hz:

Record the information found on the unit data label on this page. For the location of the unit data label, see owner’s manual. The unit has a label plate affixed to the inside partition, to the left of the control panel console.
Always supply the complete model and serial numbers of the unit when contacting an Independent Authorized Service Dealer (IASD) about parts and service.
Operation and Maintenance: Correct 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 verify all maintenance for safe operation is performed promptly, and to have the equipment inspected periodically by an IASD. Normal maintenance, service, and replacement of parts are the responsibility of the owner/operator and are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage may contribute to the need for additional maintenance or service.

Phase: Controller P/N:

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

www.generac.com/Service/DealerLocator/.

STA MAC ID:

SSID:

WARNING
CANCER AND REPRODUCTIVE HARM www.P65Warnings.ca.gov.
(000393a)

ii

Installation Guidelines For 60 Hz EcoGenTM Generators

Table of Contents

Section 1: Safety Rules & General Information
Introduction …………………………………………………………1 Read This Manual Thoroughly ………………………………1
Safety Rules ………………………………………………………..1 How to Obtain Service ………………………………………….2
General Hazards …………………………………………………..2 Exhaust Hazards ………………………………………………….3 Electrical Hazards ………………………………………………..3 Fire Hazards ………………………………………………………..3 Explosion Hazards ……………………………………………….4 Battery Hazards ……………………………………………………4 General Rules ………………………………………………………5
Before You Begin ………………………………………………..5 NEC Requirements ………………………………………………5 Standards Index ………………………………………………….6
Section 2: Unpacking and Inspection
General ………………………………………………………………..7 Required Tools …………………………………………………….7 Unpacking ……………………………………………………………7
Opening the Lid …………………………………………………..8 Enclosure Panel Removal …………………………………….8
Remove Front Access Panel …………………………………8 Intake Side Panel Removal …………………………………..9 Customer Connections and Loose Parts ……………….9 Rear Connections ………………………………………………..9 Generator Main Line Circuit Breaker ……………………10 Parts Shipped Loose ………………………………………….10 Auxiliary Shutdown Switch …………………………………11

Water Ingress Avoidance ……………………………………17 Proximity to Utilities …………………………………………..17
Verify Wi-Fi Range …………………………………………….17 Transportation Recommendations ……………………..17 Suitable Mounting Surface ………………………………….17 Placement on Roofs, Platforms, and Other Supporting Structures ………………………………………..17
Section 4: Generator Placement
Generator Placement ………………………………………….19 Fascia Installation ………………………………………………19
Section 5: Fuel Conversion / Gas Connections
Fuel Requirements and Recommendations …………21 BTU Content ……………………………………………………..21 Fuel Pressure ……………………………………………………21
Fuel Conversion …………………………………………………21 Fuel Consumption ……………………………………………..22 Fuel Line Sizing ………………………………………………….22
Natural Gas Pipe Sizing ……………………………………..23 LP Gas Pipe Sizing ……………………………………………23 Installing and Connecting Fuel Lines ………………….24 Fuel Shutoff Valve ……………………………………………..24 Flexible Fuel Line ………………………………………………24 Sediment Trap …………………………………………………..24 Checking Fuel Line Connections ………………………..25 Checking Fuel Pressure ……………………………………..25 Performing Fuel System Leak Test ………………………25 Natural Gas Installation (Typical) ………………………..26 LP Gas (Vapor) Installation (Typical) …………………..27

Section 3: Site Selection and Preparation
Site Selection …………………………………………………….13 Carbon Monoxide ……………………………………………….13
Carbon Monoxide Detectors ………………………………..13 Potential CO Entry Points ……………………………………14 Protect the Structure ………………………………………….14
Fire Prevention …………………………………………………..15 Distance Requirements ………………………………………15 Fire Codes, Standards, and Guidelines …………………16 Generator Maintenance ………………………………………16
Fresh Air for Ventilation and Cooling ………………….17

Section 6: Electrical Connections
Generator Connections ………………………………………29 Control Wiring ……………………………………………………30 Main AC Wiring ………………………………………………….31 Service Entrance Decals …………………………………….31 Common Alarm Relay (Option) ……………………………31 Battery Requirements …………………………………………32 Battery Installation ……………………………………………..32
Connecting Battery …………………………………………….32 Battery Disposal …………………………………………………32

Installation Guidelines For 60 Hz EcoGenTM Generators

iii

Section 7: Control Panel Startup/Testing
Control Panel Interface ……………………………………… 33 Using the AUTO/MANUAL/OFF Buttons …………….. 33
Generator Setup ……………………………………………….. 33 Activation ………………………………………………………… 33 Cold Smart Start ………………………………………………. 35 Setting The Exercise Timer ………………………………… 35
Before Initial Startup …………………………………………. 35 Install Wizard …………………………………………………… 35 Interconnect System Self Test Feature ………………… 35 Before starting, complete the following: ……………….. 36
Check Manual Transfer Switch Operation ………….. 39 Electrical Checks ………………………………………………. 39 Generator Tests Under Load ……………………………… 40 Checking Automatic Operation ………………………….. 41 Installation Summary ………………………………………… 41 Shutting Generator Down While Under Load or During a Utility Outage ………………………………….. 41
Section 8: Troubleshooting
Generator Troubleshooting ……………………………….. 43
Section 9: Quick Reference Guide
System Diagnosis ……………………………………………… 45
Section 10: Accessories
Section 11: Diagrams
Installation Drawing (10000037315 rev A–1 of 2) … 49 Installation Drawing (10000037315 rev B–2 of 2) … 50 Off-Grid Mode Application Schematic ………………… 51 Oil Make Up System Schematic …………………………. 52

iv

Installation Guidelines For 60 Hz EcoGenTM Generators

Safety Rules & General Information
Section 1: Safety Rules & General Information

Introduction
Thank you for purchasing this compact, high performance, air-cooled, engine- driven generator. In off-grid applications as part of an alternative energy system, the generator starts when the inverter or battery charger detects the normal power source voltage has dropped below a preset level. The generator powers the inverter and, once battery voltage rises to an acceptable level, the generator shuts down. Another off-grid application may be for use in remote locations where the generator powers a water pump for a village, campground, or livestock.
This unit is factory installed in an all-weather, metal enclosure intended exclusively for outdoor installation. This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG).
NOTE: When sized correctly, 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. This unit is also equipped with a Wi- Fi® module, which enables the generator owner to monitor generator status from anywhere they have Internet access.
NOTE: Wi-Fi® is a registered trademark of Wi-Fi Alliance®.
The information in this manual is accurate based on products produced at the time of publication. The manufacturer reserves the right to make technical updates, corrections, and product revisions at any time without notice.
Read This Manual Thoroughly

SAVE THESE INSTRUCTIONS for future reference. This manual contains important instructions that must be followed during placement, operation, and maintenance of the unit and its components. Always supply this manual to any individual that will use this unit.
Safety Rules
The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The alerts in this manual, and on tags and decals affixed to the unit, are not all inclusive. If using a procedure, work method, or operating technique that the manufacturer does not specifically recommend, verify that it is safe for others and does not render the equipment unsafe. Throughout this publication, and on tags and decals affixed to the unit, 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. Alert definitions are as follows:
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
(000001)
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
(000002)

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.(000100a)
If any section of this manual is not understood, contact the nearest Independent Authorized Service Dealer (IASD) or Generac Customer Service at 1-888-436-3722 (1-888-GENERAC), or visit www.generac.com for starting, operating, and servicing procedures. The owner is responsible for correct maintenance and safe use of the unit.
This manual must be used in conjunction with all other supporting product documentation supplied with the product.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
(000003)
NOTE: Notes contain additional information important to a procedure and will be found within the regular text of this manual.
These safety alerts cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the action or service are essential to preventing accidents.

Installation Guidelines For 60 Hz EcoGenTM Generators

1

Safety Rules & General Information
How to Obtain Service
When the unit requires servicing or repairs, contact Generac Customer Service at 1-888-GENERAC (1-888-4363722) or visit www.generac.com for assistance. When contacting Generac Customer Service about parts and service, always supply the complete model and serial number of the unit as given on its data decal located on the unit. Record the model and serial numbers in the spaces provided on the front cover of this manual.

General Hazards

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.

(000190)

DANGER
Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Failure to do so will result in death or serious injury.
(000191)

WARNING
Electrocution. Potentially lethal voltages are generated by this equipment. Render the equipment safe before attempting repairs or maintenance. Failure to do so could result in death or serious injury.
(000187)

WARNING

Loss of life. 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.

(000209b)

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.

(000130)

WARNING

Equipment damage. Only qualified service personnel may

install, operate, and maintain this equipment. Failure to follow

proper installation requirements could result in death, serious

injury, and equipment or property damage.

(000182a)

WARNING

Equipment damage. 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.

Doing so could result in death, serious injury, and

equipment damage.

(000247a)

WARNING
Electric shock. 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 equipment or property damage.
(000155a)

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.
(000115)

WARNING
Moving Parts. Keep clothing, hair, and appendages away from moving parts. Failure to do so could result in death or serious injury.
(000111)

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.

(000108)

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.

(000146)

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)

2

Installation Guidelines For 60 Hz EcoGenTM Generators

Safety Rules & General Information

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)

· Inspect the generator regularly, and contact the nearest IASD for parts needing repair or replace-
ment.

Exhaust Hazards

DANGER
Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury.
(000103)

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.

(000146)

WARNING
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.
(000178a)
· The generator must be installed and operated outdoors only.
Electrical Hazards

DANGER
Electrocution. Contact with bare wires, terminals, and connections while generator is running will result in death or serious injury.
(000144)

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. (000150)

DANGER

Electrical backfeed. Use only approved switchgear to

isolate generator from the normal power source.

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

and equipment damage.

(000237)

DANGER

Electrocution. Verify electrical system is

properly grounded before applying power.

Failure to do so will result in death or serious

injury.

(000152)

DANGER

Electrocution. Do not wear jewelry while

working on this equipment. Doing so will

result in death or serious injury.

(000188)

DANGER
Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury.
(000104)

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.

(000145)

Fire Hazards
WARNING
Fire risk. Fuel and vapors are extremely flammable. Do not operate indoors. Doing so could result in death, serious injury, or property or equipment damage. (000281)

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)

Installation Guidelines For 60 Hz EcoGenTM Generators

3

Safety Rules & General Information

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.
(000218)

DANGER
Risk of fire. Allow fuel spills to completely dry before starting engine. Failure to do so will result in death or serious injury.
(000174)

WARNING
Fire hazard. Use only fully-charged fire extinguishers rated “ABC” by the NFPA. Discharged or improperly rated fire extinguishers will not extinguish electrical fires in automatic standby generators.
(000219)

WARNING
Risk of Fire. Hot surfaces could ignite combustibles, resulting in fire. Fire could result in death or serious injury.
(000110)

WARNING

Electrocution. Refer to local codes and

standards for safety equipment required when

working with a live electrical system. Failure

to use required safety equipment could result

in death or serious injury.

(000257)

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. (000147)
Comply with regulations the Occupational Safety and Health Administration (OSHA) has established, or with equivalent standards. Also, verify that the unit is applied, used, and maintained in accordance with the manufacturer’s instructions and recommendations. Do nothing that might alter safe application/usage and render the unit in noncompliance with the aforementioned codes, standards, laws, and regulations.

Explosion Hazards

DANGER
Explosion and fire. Fuel and vapors are extremely flammable and explosive. No leakage of fuel is permitted. Keep fire and spark away. Failure to do so will result in death or serious injury. (000192)

DANGER
Explosion and fire. Connection of fuel source must be completed by a qualified professional technician or contractor. Incorrect installation of this unit will result in death, serious injury, and property and equipment damage.
(000151a)

Battery Hazards

DANGER

Electrocution. Do not wear jewelry while

working on this equipment. Doing so will

result in death or serious injury.

(000188)

WARNING

Explosion. Do not dispose of batteries in a fire. Batteries

are explosive. Electrolyte solution can cause burns and

blindness. If electrolyte contacts skin or eyes, flush with water

and seek immediate medical attention.

(000162)

WARNING

Explosion. Batteries emit explosive gases while charging.

Keep fire and spark away. Wear protective gear when

working with batteries. Failure to do so could result in

death or serious injury.

(000137a)

WARNING

Electrical shock. Disconnect battery ground

terminal before working on battery or battery

wires. Failure to do so could result in death

or serious injury.

(000164)

WARNING
Risk of burns. Batteries contain sulfuric acid and can cause severe chemical burns. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury.
(000138a)

4

Installation Guidelines For 60 Hz EcoGenTM Generators

Safety Rules & General Information

WARNING

Risk of burn. Do not open or mutilate batteries.

Batteries contain electrolyte solution which can

cause burns and blindness. If electrolyte contacts

skin or eyes, flush with water and seek immediate

medical attention.

(000163a)

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)
Always recycle batteries in accordance with local laws and regulations. Contact your local solid waste collection site or recycling facility to obtain information on local recycling processes. For more information on battery recycling, visit the Battery Council International website at: http://batterycouncil.org

General Rules

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.

(000190)

DANGER

Electrical backfeed. Use only approved switchgear to

isolate generator from the normal power source.

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

and equipment damage.

(000237)

WARNING

Equipment damage. Only qualified service personnel may

install, operate, and maintain this equipment. Failure to follow

proper installation requirements could result in death, serious

injury, and equipment or property damage.

(000182a)

WARNING

Electrocution. Refer to local codes and

standards for safety equipment required when

working with a live electrical system. Failure

to use required safety equipment could result

in death or serious injury.

(000257)

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.(000100a)
· Follow all safety precautions in the owner’s manual, installation guidelines manual, and other documents included with the equipment.
· Never energize a new system without opening all disconnects and breakers.
· Always consult local code for additional requirements for where unit is being installed.
· Incorrect installation can result in personal injury and damage to the unit. It may also result in the warranty being suspended or voided. All instructions listed below must be followed including location clearances and pipe sizes.
Before You Begin
· Contact local inspector or city hall to be aware of all federal, state, and local codes which could impact installation. Secure all required permits before installing.
· Fully comply with all relevant NEC, NFPA, and OSHA standards, as well as all federal, state, and local building and electric codes. This unit must be installed in accordance with current NFPA 37 and NFPA 70 standards, and any other federal, state, and local codes for minimum distances from other structures.
· Verify capacity of NG meter or LP tank in regards to providing sufficient fuel for both the unit and other household and operating appliances.
NEC Requirements
Local code enforcement may require Arc Fault Circuit Interrupters (AFCIs) to be incorporated into the transfer switch distribution panel. The transfer switch provided with this generator has a distribution panel which will accept AFCIs (pre-wired transfer switches only).
Siemens Part No. Q115AF – 15A or Q120AF – 20A can be obtained from a local electrical wholesaler and will simply replace any of the single pole circuit breakers supplied in the pre-wired transfer switch distribution panel.

Installation Guidelines For 60 Hz EcoGenTM Generators

5

Safety Rules & General Information

Standards Index

WARNING

Loss of life. 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.

(000209b)

Strictly comply with all applicable national, state, and local laws, as well as codes or regulations pertaining to the installation of this engine- generator power system. Use the most current version of applicable codes or standards relevant to the local jurisdiction, generator used, and installation site.
NOTE: Not all codes apply to all products and this list is not all-inclusive. In the absence of pertinent local laws and standards, the following publications 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
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 110: Standard for Emergency and Standby Power Systems
10. NFPA 211: Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances
11. NFPA 220: Standard on Types of Building Construction
12. NFPA 5000: Building Code
13. International Building Code **
14. Agricultural Wiring Handbook ***
15. Article X, NATIONAL BUILDING CODE
16. ASAE EP-364.2 Installation and Maintenance of Farm Standby Electric Power

17. ICC:IFGC
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.nfpa.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, St. Joseph, MI 49085

6

Installation Guidelines For 60 Hz EcoGenTM Generators

Unpacking and Inspection
Section 2: Unpacking and Inspection

General
NOTE: Carefully inspect contents for damage after unpacking. Unpack and inspect unit immediately upon delivery to identify any damage which may have occurred in transit. Any claims for shipping damage need to be filed as soon as possible with the freight carrier. This is especially important if the unit will not be installed for a period of time.
· This standby generator set is ready for installation with a factory supplied and pre-mounted base pad and has a weather protective enclosure intended for outdoor installation only.
· If any loss or damage is noted at time of delivery, have delivery person(s) note all damage on the freight bill, or affix their signature under consignor’s memo of loss or damage.
· If a loss or damage is noted after delivery, separate damaged materials and contact carrier for claim procedures.
· “Concealed damage” is understood to mean damage to contents of a package not evident at time of delivery, but discovered later.
Required Tools
· General SAE and Metric hand tools
­ Wrenches
­ Sockets
­ Screwdrivers
· Standard electrician’s hand tools
­ Drill and bits for mounting and routing conduits
· 4 mm hex key (for access to customer connections)
· 3/16 in hex key (test port on fuel regulator) · Manometer (for fuel pressure checks) · Meter capable of measuring AC/DC voltage and
frequency
· Torque wrenches

Unpacking
1. Remove outer shipping carton. 2. See Figure 2-1. Remove wood frame.
000427
Figure 2-1. Crated Generator 3. See Figure 2-2. Lid will be locked. A set of keys is
attached to the cardboard sheet on top of the unit. An additional set is attached to the pallet bracket on the front intake end of the unit. Remove keys from cardboard and pallet bracket.
006729
Figure 2-2. Keys As Shipped NOTE: The enclosed keys provided with this unit are intended for service personnel only.

Installation Guidelines For 60 Hz EcoGenTM Generators

7

Unpacking and Inspection

IMPORTANT NOTE: DO NOT perform next step until generator has been transported to installation site.
4. See Figure 2-3. Remove bolts and pallet brackets (A). Exercise caution when removing generator. Dragging it off pallet will damage base. The unit must be lifted from wooden pallet to remove.
NOTE: Bolts and pallet brackets are provided only for shipping purposes and can be discarded after removal.

Enclosure Panel Removal
Generator installation requires removal of front panel and intake side panel. Remove these panels when necessary. Proceed as follows to remove the panels.
Remove Front Access Panel
See Figure 2-5. Remove front access panel (A) by lifting straight up and out once lid is open.
NOTE: Always lift front access panel straight up before pulling away from enclosure (B and C). Do not pull panel away from the enclosure before lifting up (D).

B

A

A

000426

Figure 2-3. Pallet Bracket Locations

Opening the Lid

1. Use keys to open generator lid.

C

2. See Figure 2-4. Two locks (A) secure lid; one on each side. Press down on lid above side lock, and
unlock latch to correctly open lid.

A

A

Figure 2-4. Opening the Lid

009209

3. Repeat for other side. Lid may appear stuck if pressure is not applied from the top.
NOTE: Always verify side locks are unlocked before attempting to lift lid.

D
009210
Figure 2-5. Remove Front Access Panel

8

Installation Guidelines For 60 Hz EcoGenTM Generators

Unpacking and Inspection

Intake Side Panel Removal
See Figure 2-6. The intake side panel (A) must be removed to access battery compartment, fuel regulator, and sediment trap.
1. Raise lid and remove front panel.
2. Use a hex key to remove two mounting screws (B) and the hex screw on the L-bracket.
3. Lift intake panel up and away from generator.
4. Inspect for any hidden freight damage. Contact freight carrier if damage is present.
NOTE: Always lift intake side panel straight up before pulling away from enclosure. Do not pull panel away from enclosure before lifting up (D).

Customer Connections and Loose Parts
See Figure 2-7 and Figure 2-8 for customer connections and loose parts location. Figure 2-10 illustrates parts shipped loose.
E
C

B A
C D

A

D

B

001800

A Customer electrical connection area (behind access panel)
B Fuel regulator with sediment trap C Battery compartment (battery not supplied) D Positive (+) and negative (-) battery cables E Location of “Loose Shipped Parts”
Figure 2-7. Customer Connection Area and Loose Parts Location

Rear Connections

E

A

002961

B

Figure 2-6. Intake Side Panel Removal

C

Installation Guidelines For 60 Hz EcoGenTM Generators

D
001802
A Wi-Fi module B Main AC/Control wiring hole for 1-1/4 in conduit C Main AC/Control wiring hole for 3/4 in conduit D Fuel connection hole E Auxiliary shutdown switch
Figure 2-8. Rear Connections
NOTE: The generator is equipped with a Wi-Fi module. See Wi-Fi module owner’s manual for further instruction.
9

Unpacking and Inspection

Generator Main Line Circuit Breaker Parts Shipped Loose

See Figure 2-9. The 2-pole circuit breaker (generator disconnect) (A) is rated according to relevant specifications.

F

E

B

B

A

001810

Figure 2-9. Generator Main Line Circuit Breaker

Breaker can be locked in OFF (OPEN) position for security during maintenance or transfer switch service. Use an appropriately-sized padlock (not included) with a shackle long enough to pass through both lock tabs (B).
NOTE: DO NOT leave breaker disconnect locked in the OFF (OPEN) position during normal generator operation. Leaving breaker in the OFF (OPEN) position will prevent generator from powering structure during a power outage when placed in AUTO mode.

C

D

A

003599

A Keys B Flexible fuel line C Battery terminal cap D Rubber mounts E Fascia F Oil Drain Pump Kit G Decal–Service entrance warning (not shown) H Decal–Through conductors warning (not shown) J Decal–Service disconnect (not shown) K Owner’s and Installation manuals (not shown) L Wi-Fi manual (not shown) M Wi-Fi Quick Start Guide (not shown)
Figure 2-10. Parts Shipped Loose

10

Installation Guidelines For 60 Hz EcoGenTM Generators

Auxiliary Shutdown Switch

CAUTION

Equipment Damage. The auxiliary shutdown switch is

not to be used to power down the unit under normal

operating circumstances. Doing so will result in

equipment damage.

(000399)

All generators are equipped with an external means of shutting down the generator which complies with the latest NEC code requirement. The primary generator shutdown sequence is described in Control Panel Startup/ Testing.
See Figure 2-11. An auxiliary shutdown switch is provided on the exterior of the generator back panel. This switch shuts down the generator and disables restarts.

005491
Figure 2-11. External Auxiliary Shutdown Switch
NOTE: Whenever possible, perform primary shutdown procedure before disabling generator with auxiliary shutdown switch.
See Figure 2-12. There is also an auxiliary shutdown switch located inside the generator.

005492
Figure 2-12. Internal Auxiliary Shutdown Switch
Generator will not start if either switch is OPEN (O). Controller displays an “Auxiliary Shutdown” alarm, and red LED “Alarm” light illuminates until switch or switches are CLOSED (I), and alarm is cleared by pressing OFF mode button, and then ENTER. Once cleared, generator can be placed back in AUTO or MANUAL.
Installation Guidelines For 60 Hz EcoGenTM Generators

Unpacking and Inspection 11

Unpacking and Inspection
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12

Installation Guidelines For 60 Hz EcoGenTM Generators

Site Selection and Preparation
Section 3: Site Selection and Preparation

Site Selection
Site selection is critical for safe generator operation. It is important to discuss these factors with the installer when selecting a site for generator installation:
· Carbon monoxide
· Fire prevention
· Fresh air for ventilation and cooling
· Water ingress prevention
· Proximity to utilities
· Suitable mounting surface
The following pages describe each of these factors in detail.
NOTE: The term “structure” is used throughout this section to describe the home or building where generator is being installed. Illustrations depict a typical residential home. However, instructions and recommendations presented in this section apply to all structures regardless of type.

Carbon Monoxide
DANGER
Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury.
(000103)
IMPORTANT NOTE: Move to fresh air immediately and seek medical attention if you feel sick, dizzy, or weak while the generator is running or after it stops.
Generator exhaust contains carbon monoxide (CO)–a poisonous, potentially lethal gas that cannot be seen or smelled. The generator must be installed in a well ventilated area away from windows, doors, and openings. The selected location should not allow exhaust gases to be drawn into structures where people or animals may be present.
Carbon Monoxide Detectors
See Figure 3-1. CO detectors (K) must be used to monitor for CO and to warn individuals about the presence of CO. CO detectors should be installed and tested in accordance with the CO detector manufacturer’s instructions and warnings. Contact local building inspection department for any applicable requirements concerning CO detectors.
IMPORTANT NOTE: Common smoke alarms do NOT detect CO gas. Do not rely on smoke alarms to protect residents or animals from CO. The only way to detect CO is to have functioning CO alarms.

Installation Guidelines For 60 Hz EcoGenTM Generators

13

Site Selection and Preparation

Potential CO Entry Points
See Figure 3-1. Generator exhaust can enter a structure through large openings, such as windows and doors. However, exhaust and CO can also seep into the structure through smaller, less obvious openings.

Protect the Structure
Verify structure itself is correctly caulked and sealed to prevent air from leaking in or out. Voids, cracks, or openings around windows, doors, soffits, pipes, and vents can allow exhaust gas to be drawn into the structure.
Some examples of potential entry points are described and included in, but not limited to, the accompanying table.

C

K

C

A

A

B

A A A

H

F

D

E A

J

G

Figure 3-1. Carbon Monoxide–Potential Entry Points

A
008781

ID

Entry Point

Description / Comments

A Windows and doors Architectural details which can be (or are) opened to admit fresh air into the structure.

B Garage door

CO can leak into garage if door is open, or does not seal correctly when closed.

C Attic vent

Attic vents, ridge vents, crawl space vents, and soffit vents can all admit generator exhaust.

D Basement windows Windows or hatches allowing ventilation to or from lower level of a structure.

E

Furnace intake / exhaust vent

Air intake and exhaust pipes for furnace.

F Wall cracks

Includes (but not limited to) cracks in wall, foundation, mortar, or air gaps around doors, windows, and pipes. See Protect the Structure.

G Dryer vent

Exhaust duct for clothes dryer.

H Airflow restrictions

Structural corners and locations with heavy vegetation restrict airflow. Exhaust gases can collect in such areas.

IMPORTANT NOTE: Mechanical and gravity outdoor air intake openings for HVAC supply

J

Make up air system

air systems shall be located not less than 10 feet (3048mm) horizontally from the generator enclosure. See Section 401 in the ICC Mechanical Code for any additional

requirements.

14

Installation Guidelines For 60 Hz EcoGenTM Generators

Site Selection and Preparation

Fire Prevention
The generator must be installed at a safe distance away from combustible materials. Engine, alternator, and exhaust system components become very hot during operation. Fire risk increases if unit is not correctly ventilated, is not correctly maintained, operates too close to combustible materials, or if fuel leaks exist. Also, accumulations of flammable debris within or outside the generator enclosure may ignite.

Distance Requirements
See Figure 3-2. Minimum clearances must be maintained around the generator enclosure. These clearances are primarily for fire prevention, but also to ensure sufficient room for removing front and end panels for maintenance purposes.

C

D F

B A

A

A

G

C

C

C

E

008782

Figure 3-2. Generator Distance Requirements

ID

Description

Definition

A

Front and end clearance

Minimum clearance from the front and ends of generator must be 3 ft (0.91 m). This includes shrubs, bushes, and trees.

B Rear clearance

Fuel and electrical connections are made here. 18 in (457 mm) minimum clearance per NFPA testing, labeling, and listing, unless state or local codes dictate otherwise.

C

Windows, vents, and openings

No operable windows, doors, vents, window wells, or openings in the wall are permitted near any point of the generator. See Potential CO Entry Points for more information.

D Existing wall

The generator should not be placed closer than 18 in (457 mm) from existing walls.

E Removable fence

A removable barrier (non-permanent; without footings) installed as a visual surround. Removable fence panels for servicing cannot be placed less than 3 ft (0.91 m) in front of the generator.

F

Overhead clearance

5 ft (1.52 m) minimum distance from any structure, overhang, or projections from wall. DO NOT install under wooden decks or structures.

G

Maintenance and servicing

Maneuvering space around generator for performing routine maintenance tasks such as battery replacement and engine service. Do not attempt to conceal generator with shrubs, bushes, or plants.

Installation Guidelines For 60 Hz EcoGenTM Generators

15

Site Selection and Preparation

Fire Codes, Standards, and Guidelines
Generator installation must comply strictly with ICC IFGC, NFPA 37, NFPA 54, NFPA 58, and NFPA 70 standards. These standards prescribe the minimum safe clearances around and above the generator enclosure.
NFPA 37
NFPA 37 is the The National Fire Protection Association’s standard for the installation and use of stationary combustion engines. Its requirements limit the spacing of an enclosed generator set from a structure or wall, and require generator to be located where it is readily accessible for maintenance, repair, and first responders.
NFPA 37, Section 4.1.4, Engines Located Outdoors: Engines, and their weatherproof housings if provided, 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 the following conditions exist:
1. The adjacent wall of the structure has a fire resistance rating of at least one 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 compliance are by means of full scale fire test or by calculation procedures.
Because of the limited spaces frequently available for installation, it has become apparent that exception (2) would be beneficial for many residential and commercial installations. The manufacturer contracted with an independent testing laboratory to run full scale fire tests.
NOTE: The Southwest Research Institute (SwRI) is a nationally recognized third party testing and listing agency. SwRI testing approves 18 in (457 mm) installation minimum from the rear panel of the generator to an adjacent structure for fire protection.
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 distances. The enclosure is constructed of non- combustible materials, and the 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.

002158
Figure 3-3. Southwest Research Institute Marking
http://www2.swri.org/www2/listprod/ DocumentSelection.asp?ProductID=973&IndustryID=2
Based on this testing and the requirements of NFPA 37, Sec 4.1.4, the guidelines for installation of the generators listed above are changed to 18 in (457 mm) from the back side of the generator to a stationary wall or building For adequate maintenance and airflow clearance, the area above the generator should be at least 5 ft (1.52 m) with a minimum of 3 ft (0.91 m) at the front and ends of the enclosure. This includes 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. See Figure 3-2 and the accompanying descriptions.
Generator Maintenance
Regular maintenance is crucial for minimizing exhaust emissions and reducing the risk of fire or equipment failure. For example:
· A dirty air filter or low engine oil level may cause engine to overheat.
· Incorrect spark plug gaps may cause engine backfiring and incomplete combustion.
IMPORTANT NOTE: See Maintenance section of generator owner’s manual to view a table of scheduled maintenance tasks and procedures. Perform all maintenance tasks as directed.

16

Installation Guidelines For 60 Hz EcoGenTM Generators

Site Selection and Preparation

Fresh Air for Ventilation and Cooling
Install unit where air inlet and outlet openings will not become obstructed by leaves, grass, snow, etc. If prevailing winds will cause blowing or drifting, consider using a windbreak at a safe distance to protect the unit.

Suitable Mounting Surface
See Figure 3-4. Prepare a rectangular area approximately 5 in (127 mm) deep (A) and approximately 3 in (76.2 mm) longer and wider (B) than the generator on all sides.

Water Ingress Avoidance
· Select a location on high ground where water levels will not rise and flood the generator. This unit should not operate in, or be subjected to, standing water.
· Install unit where rain gutter downspouts, roof runoff, landscape irrigation, water sprinklers, or sump pump discharge does not flood unit or spray enclosure, including any air inlet or outlet openings.
· Excess moisture can cause excess corrosion and decrease life expectancy of the unit.
Proximity to Utilities
· Contact local utility providers and verify proposed site selection meets all required utility placement requirements before installation. This could affect warranty coverage.
· Remember, laws and or codes may regulate distance and location of unit to specific utilities.
· It is recommended to pick a location where the generator is as close as possible to the transfer switch and the fuel supply, while verifying the site location conforms to the rest of the Site Selection section.
Verify Wi-Fi Range
See Wi-Fi manual shipped with the unit if planning to use the Wi-Fi feature.
Transportation Recommendations
Use a suitable cart or equipment to carry generator, including wooden pallet, to installation site. Place cardboard between cart and generator to prevent any damage or scratches to generator.
Do not lift, carry, or move generator by grasping the louvers. Doing so may bend or damage the sheet metal.

B
A
000856
Figure 3-4. Compacted Gravel or Concrete Pad
Select base type as desired or as required by local laws or codes. The generator is typically placed on pea gravel, crushed stone, or a concrete pad. Follow all applicable codes if a concrete pad is required. Verify surface where generator will be mounted is compacted, leveled, and will not erode over time. Generator must be level within 0.5 in (13 mm) all around.
Placement on Roofs, Platforms, and Other Supporting Structures
Where required to place generator on a roof, platform, deck, or other supporting structure, generator must be placed in accordance with the requirements in NFPA 37, Section 4.1.3. Generator can be located 18 in (457 mm) from structures having combustible walls and 5 ft (1.52 m) from any operable opening in the structure. Surface beneath the generator and beyond must be noncombustible to a minimum distance of 12 in (30.5 cm). Contact local Building Inspection Department or fire department to determine which noncombustible materials are approved for installation.

Installation Guidelines For 60 Hz EcoGenTM Generators

17

Site Selection and Preparation
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18

Installation Guidelines For 60 Hz EcoGenTM Generators

Section 4: Generator Placement

Generator Placement

Generator Placement
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 base.

Three 3/8 in (or M10) lag bolts (not supplied) are recommended for securing the generator to a concrete pad.
NOTE: The top of the generator carton has a template which can be used to mark the concrete pad to pre-drill the mounting holes.

Figure 4-1. Composite Pad

000612

The composite pad allows the generator to be placed on two types of surfaces:
· on 5 in (127 mm) of compacted pea gravel or crushed stone
· on a concrete pad
See local codes to verify what type of site base is required. If a concrete pad is required, all federal, state, and local codes must be followed. Place generator, with composite pad attached, and position correctly as per dimensional information given in Site Selection and Preparation.
NOTE: Generator must be level within 0.5 in (13 mm).
NOTE: See Figure 4-2. DO NOT remove composite pad for mounting generator to concrete. The composite pad is pre-drilled to accommodate mounting bolts.

Fascia Installation
1. Locate the four threaded black rubber bumpers supplied with the loose parts. (See Parts Shipped Loose.)
2. See Figure 4-3. Remove bumpers from bag and screw into threaded holes located inside the end pieces of the fascia (two each) opposite one another (A). B A
C

001804
Figure 4-2. Mounting Hole Locations
Three mounting holes are available if codes require securing generator to concrete. Mounting holes are located inside the generator compartment–two in front and one in back.
Installation Guidelines For 60 Hz EcoGenTM Generators

Figure 4-3. Fascia Installation

000614

3. Snap one of the end pieces into one of the front/ rear pieces of fascia. Repeat this action with the other two remaining pieces of fascia (B).
NOTE: Do not assemble all four pieces together at this point.
4. Place both assemblies at the generator base and fit the rubber mounts into the lifting holes in the generator base (C).
5. Once aligned, snap together the two remaining connection points.

19

Generator Placement
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20

Installation Guidelines For 60 Hz EcoGenTM Generators

Fuel Conversion / Gas Connections
Section 5: Fuel Conversion / Gas Connections

Fuel Requirements and Recommendations
DANGER
Explosion and fire. Fuel and vapors are extremely flammable and explosive. No leakage of fuel is permitted. Keep fire and spark away. Failure to do so will result in death or serious injury.
(000192)
NOTE: NG is lighter than air and will collect in high areas. LP gas is heavier than air and will settle in low areas.
LP gas should only use a vapor withdrawal system. This type of system uses vapors formed above liquid propane in the storage tank. The unit will run on NG or LP gas, but has been factoryconfigured to run on NG.
NOTE: Should the primary fuel need to be changed to LP gas, the fuel system needs to be reconfigured. See Fuel Conversion for instructions on converting the fuel system.
BTU Content Recommended fuels should have a BTU content of at least 1,000 BTU/ft3 (37.26 MJ/m3) for NG; or at least 2,500 BTU/ft3 (93.15 MJ/m3) for LP gas.
NOTE: BTU fuel content information is available from fuel supplier.
Fuel Pressure Required fuel pressure for NG is 3.5­7.0 in water column (0.87­1.74 kPa) at the generator fuel inlet. Required fuel pressure for LP vapor is 10­12 in water column (2.49­ 2.99 kPa) at the generator fuel inlet.
NOTE: The primary regulator for the LP gas supply is NOT INCLUDED with generator.
NOTE: All pipe sizing, construction, and layout must comply with NFPA 54 for NG applications and NFPA 58 or ICC IFGC for LP gas applications. Verify fuel pressure NEVER drops below required specification once generator is installed. See the NFPA website at www.nfpa.org for further information regarding NFPA requirements.
Always contact local fuel suppliers or fire marshal to verify codes and regulations for correct installation. Local codes will mandate correct routing of gaseous fuel line piping around gardens, shrubs, and other landscaping.

Piping strength and connections should be given special consideration for installations in areas at risk for flooding, tornadoes, hurricanes, earthquakes, and unstable ground. IMPORTANT NOTE: Use an approved pipe sealant or joint compound on all threaded NPT fittings. NOTE: All installed gaseous fuel piping must be purged and leak tested prior to initial startup in accordance with local codes, standards, and regulations.
Fuel Conversion
Proceed as follows to convert from NG configuration to LP vapor: See Figure 5-1. The orange fuel conversion knob (A) is located above the fuel mixer (B). Turn fuel conversion knob towards marked fuel source arrow until it stops to select fuel type. Fuel conversion knob will rotate 180° and slide into mixer body when converting to LP gas. NOTE: The fuel selection (LP/NG) must be entered on the controller during initial startup using the Install Wizard Menu Map navigation menu, or in EDIT menu under “Fuel Selection.”
B A
009091
Figure 5-1. Fuel Conversion Knob Location

Installation Guidelines For 60 Hz EcoGenTM Generators

21

Fuel Conversion / Gas Connections

Fuel Consumption

Generator

Natural Gas

1/2 Load

Full Load

1/2 Load

Propane

Full Load

15 kW

5.52 / 195

7.87 / 278

1.84 / 6.95 / 66.8

2.76 / 10.45 / 100

• Natural gas is in m3/h / ft3/h ** Propane is in gal/h (LP) / L/h (LP) / ft3/h (LPV) *** Values given are approximate These are approximate values. Use the appropriate spec sheet or fuel data decal for specific values. Verify gas meter is capable of providing enough fuel flow to include household appliances and all other loads.

NOTE: The fuel supply and pipe MUST be sized at 100% load BTU/h (Megajoule/h) rating.

Always see fuel data label for the correct BTU/h or Megajoule/h, and required fuel pressures:
­ Natural Gas: BTU/h = ft3/h x 1000 Megajoules/h = m3/h x 37.26
­ Liquid Propane Gas (Vapor): BTU/h = ft3/h x 2500 Megajoules/h = m3/h x 93.15

Fuel Line Sizing
Selecting the correct size fuel line is crucial to correct operation of the unit.
IMPORTANT NOTE: Generator inlet size DOES NOT dictate the size of gas pipe to be used!
For further information see NFPA 54 for NG, or NFPA 58 or ICC IFGC for LP.
Measure distance from generator to fuel source.
IMPORTANT NOTE: The generator should be plumbed directly from the fuel source, not off the end of an existing low pressure system.

22

Installation Guidelines For 60 Hz EcoGenTM Generators

Fuel Conversion / Gas Connections

Natural Gas Pipe Sizing
To determine correct NG pipe size, find the kW rating of generator in the left column, and trace to the right. The number to the right is maximum length (measured in ft / m) allowed for the pipe sizes on top. Pipe sizes are measured by trade size diameter to include any fittings, valves (must be full flow), elbows, tees, or angles.

NOTE: See Table B.3.2 in NFPA 54 or Table A.2.2 in the ICC IFGC, Equivalent Lengths of Pipe Fittings and Valves for the correct values to be added to overall fuel piping length. Tables are based on schedule 40 black pipe. If installing any other piping system, follow pipe sizing charts for selected piping system.

Table 5-1. NG Pipe Sizing

Pipe Size (in / mm)

For 5­7 in Water Column (1.24­1.74 kPa)
Allowable Pipe Distances (ft / m)

For 3.5­5 in water column (0.87­1.24 kPa)

0.75 / 19

1 / 25

1.25 / 32

1.5 / 38

2 / 51

1 / 25

1.25 / 32

1.5 / 38

15 kW

10 / 3.1

35 / 10.7 140 / 42.3 300 / 91.4

—

10 / 3.1

60 / 18.3 125 / 38.1

LP Gas Pipe Sizing
To determine correct LP gas pipe size, find the kW rating of generator in the left column, and trace to the right. The number to the right is maximum length (measured in ft / m) allowed for pipe sizes on top. Pipe sizes are measured by trade size diameter to include any fittings, valves (must be full flow), elbows, tees, or angles. See Table B.3.2 in NFPA 54 or Table A.2.2 in the ICC IFGC, Equivalent Lengths of Pipe Fittings and Valves for the correct values to be added to overall fuel piping length.

NOTE: Pipe sizes are from the outlet of the second stage regulator to the fuel shutoff valve. Table is based on schedule 40 black pipe. If installing any other piping system, follow the pipe size charts for the selected piping system.
NOTE: Recommended minimum LP tank size is 250 gal (946 L). Contact LP provider to correctly size LP tank to generator. Vertical tanks, which are measured in pounds (or kilograms), are permitted if correctly sized for the generator. Do not connect generator to a 20 or 30 lbs LP
tank.

Table 5-2. LP Gas Pipe Sizing

Pipe Size (in / mm)

For 10­12 in water column (2.49­2.99 kPa)
Allowable Pipe Distances (ft / m)

0.75 / 19

1 / 25

1.25 / 32

15 kW

40 / 12.2

175 / 53.3

550 / 167.6

Installation Guidelines For 60 Hz EcoGenTM Generators

23

Fuel Conversion / Gas Connections
Installing and Connecting Fuel Lines .

DANGER
Explosion and fire. Fuel and vapors are extremely flammable and explosive. No leakage of fuel is permitted. Keep fire and spark away. Failure to do so will result in death or serious injury.
(000192)
IMPORTANT NOTE: NG and LP gas are highly volatile substances. Strictly adhere to all safety procedures, codes, standards, and regulations. Fuel line connections should be made by a certified contractor familiar with local codes. Always use AGAapproved gas pipe and a quality pipe sealant or joint compound. Verify capacity of NG meter or LP tank to provide sufficient fuel for both the generator and other operating appliances.
Fuel Shutoff Valve See Figure 5-2. The generator will require an external manual fuel shutoff valve (A) on the fuel line. NOTE: Fuel shutoff valve must be installed at a readily accessible location, and within 6 ft (1.8 m) of generator fuel inlet.
A
B C
001816
Figure 5-2. Sediment Trap, Fuel Shutoff Valve with Manometer Port, and Flexible Fuel Line
Figure 5-3 illustrates a fuel shutoff valve with a manometer port for making fuel pressure checks. This optional accessory fuel shutoff valve permits making pressure checks for diagnostic purposes without going into the generator enclosure.

000743
Figure 5-3. Fuel Shutoff Valve with Manometer Port
Fuel shutoff valves available through an IASD: · 1/2 in ball valve, part number 0K8752 · 3/4 in ball valve, part number 0K8754 · 1 in ball valve, part number 0K8184 · 1-1/4 in ball valve, part number 0L2844 · 1-1/2 in ball valve, part number 0L2845
Flexible Fuel Line
See Figure 5-2. When connecting flexible fuel line (B) to generator, use a listed assembly meeting the requirements of ANSI Z21.75/ CSA 6.27–Connectors for Outdoor Gas Appliances and Manufactured Homes or AGAapproved flexible fuel line in accordance with local regulations.
Flexible fuel line must not be connected directly to generator fuel inlet. Always connect flexible fuel line to an approved gas fitting.
The purpose of flexible fuel line is to isolate vibration from the generator to reduce possibility of a gas leak at one of the connection points.
NOTE: Follow all installation instructions and warnings provided with flexible fuel line. Do not remove any labels or tags. Flexible fuel line must be installed horizontally, and must be installed between fuel shutoff valve and generator fuel inlet.
Sediment Trap
See Figure 5-2. Some local codes require a sediment trap (C). The fuel regulator connection has an integrated sediment trap.
The sediment trap must be cleaned periodically according to local codes. See owner’s manual for more information.

24

Installation Guidelines For 60 Hz EcoGenTM Generators

Fuel Conversion / Gas Connections

Checking Fuel Line Connections
Checking Fuel Pressure
Proceed as follows to check fuel pressure at the regulator in the generator:
1. Close fuel supply valve. 2. See Figure 5-4. Remove top fuel pressure test port
from regulator and install fuel pressure tester (manometer).
3. Open fuel supply valve and verify fuel pressure is within specified values.
4. Record static fuel pressure:
NOTE: Fuel pressure can also be tested at the manometer port on fuel shutoff valve shown in Figure 5-2.
NOTE: See Fuel Data Decal or spec sheet for correct fuel pressure specifications. If fuel pressure is not within specifications, contact local fuel supplier.
5. Close fuel supply valve when completed, but keep manometer connected for future tests of the generator while starting, running, and under loads.

Performing Fuel System Leak Test
DANGER
Explosion and fire. Fuel and vapors are extremely flammable and explosive. No leakage of fuel is permitted. Keep fire and spark away. Failure to do so will result in death or serious injury.
(000192)
All products are factory-tested before shipping to verify the performance and integrity of the fuel system. However, it is important to perform a final fuel system leak test before starting the generator. The entire fuel system should be tested from supply to regulator. See Figure 5-5. Perform a final fuel system leak test after generator installation. The test will identify possible leaks at all connection points (A). It is best practice to perform a fuel system leak test during normally-scheduled maintenance.
A

A

001807
Figure 5-4. Checking Pressure with Manometer A
004038
Figura 5-5. Connection Points to Leak Check Inspect for leaks by spraying all connection points with a non-corrosive gas leak detection fluid. The solution should not be blown away or form bubbles.

Installation Guidelines For 60 Hz EcoGenTM Generators

25

Fuel Conversion / Gas Connections
Natural Gas Installation (Typical)
A D
E I

F C

B

G

H

J
008965

NG BTU/h = ft3/h X 1000

Megajoules/h = m3/h X 37.26

A Fuel data decal

B Minimum distance from rear obstruction–see Distance Requirements

C Manual fuel shutoff valve (pressure port optional) Must be located no more than 6 ft (1.83 m) away from fuel inlet

D Pipe fittings (field supplied)

E Flexible fuel line

F Check clearance with gas provider

G Size gas meter for 100% generator load plus all appliance loads

H For underground installations, verify piping system for code compliance

I Reinforcing rod with clamps

J To gas main

Figure 5-6. Natural Gas Installation (typical)

26

Installation Guidelines For 60 Hz EcoGenTM Generators

LP Gas (Vapor) Installation (Typical)
A D
E

G

H

Fuel Conversion / Gas Connections
JK L

C B

F
008966

LPG BTU/h = ft3/h X 2500

Megajoules/h = m3/h X 93.15

A Fuel data decal

B Minimum distance from rear obstruction–see Distance Requirements

C Manual fuel shutoff valve (pressure port optional) Must be located no more than 6 ft (1.83 m) away from fuel inlet.

D Pipe fittings (field supplied)

E Flexible fuel line

F Verify minimum distance requirements for regulator vent according to local gas codes.

G Clamp

H Secondary fuel pressure regulator

J

Manual shutoff valve

K Primary fuel pressure regulator

L Fuel tank–sized large enough to provide required MJ/BTU for generator and ALL connected appliance loads. Be sure to correct for weather evaporation.

Figure 5-7. LP Gas (Vapor) Installation (typical)

Installation Guidelines For 60 Hz EcoGenTM Generators

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Fuel Conversion / Gas Connections
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28

Installation Guidelines For 60 Hz EcoGenTM Generators

Section 6: Electrical Connections
Generator Connections
See Figure 6-1. The electrical wiring enclosure is located behind an access panel on the intake end of the unit. Remove intake side panel as directed in Intake Side Panel Removal, and then remove access panel. Connect wires according to diagram and tables.
1. Remove main AC / control wiring knock-out plugs from back of generator.
2. Using appropriate wiring hole, install conduit and main AC and control wires between generator and transfer switch.
3. Close unused hole with a NEMA 3R rated plug (field-supplied).
NOTE: All conductors are to be rated for minimum 300V. Control system interconnections may consist of N1, N2, and T1, and leads 23 and 194. All of the generator control wiring circuits are Class 1 remote control or signaling circuits. Class 1 circuits are required to be installed in accordance with Part 1 of NEC Article 300 and with a NEC recognized Chapter 3 wiring method. The use of low voltage cables for the generator control circuit wiring is prohibited. See instruction manual of the specific engine generator for wiring connection details. Recommended wire gauge sizes for this wiring depends on wire length, as recommended in Table 6-3.
Exception: Conductors of AC and DC circuits, rated 1000 volts nominal or less, shall be permitted to occupy the same equipment, cable, or conduit. All conductors shall have an insulation rating equal to at least the maximum circuit voltage applied to any conductor within the equipment, cable, or conduit. See NEC 300.3(C)(1).
4. See Figure 6-1. Strip insulation from wire ends. Do not remove excessive insulation. Route sense wires through supplied wire tie (C1), and connect to sense wire terminal block (B). Push down on spring loaded connection point with a flat head screwdriver, insert wire, and release.
5. Using the same process, route control wires through second supplied wire tie (C2), and connect to control wire terminal block (A).
6. When all wires are securely connected to correct terminals, tighten wire ties and clip excess length.
NOTE: Only bare wire should be inserted into each terminal. Do not insert any wire insulation into terminals.
NOTE: Damage caused by mis-wiring of the interconnect wires is not warrantable.

Electrical Connections

Installation Guidelines For 60 Hz EcoGenTM Generators

29

Electrical Connections
Control Wiring

10

1

DC GROUND

2 194
2 + 12 VDC

3 23
3TRANSFER

1 N1

1 UTILITY

2

SENSE
N2

2

3 T1
VAC LOAD 3 SUPPLY

A E1

B

C1

C2

10

1

DC GROUND

2 194
2 + 12 VDC

3 23
3TRANSFER

1 N1
1 UTILITY 2 SENSE
N2
2
3 T1
VAC LOAD 3 SUPPLY

E2

J

H

D

F

Figure 6-1. Electrical Wiring Connections

ID Description A Control wire terminal block B Sense wire terminal block C1 Wire tie for sense wires

Table 6-1. Electrical Wiring Connection Points

ID Description

ID Description

C2 Wire tie for control wires

E2 Power lug E2

D Neutral lug

F Ground stud

E1 Power lug E1

G Ground lug

G

005810

ID Description H Neutral stud J Neutral bar —-

Table 6-2. Customer Wiring Connections

Terminal Numbering Decal

Wire Numbers

YELLOW ***

N1 & N2 – 240 VAC – Sensing for utility dropout and pickup. Required for battery heater and oil heater.

BLUE *

T1 – Fused 120 VAC for battery charger. Breather heater requires T1 connection to 120V.

Table 6-3. Control Wire Recommended Length and Size (Copper Conductors Only)

Maximum Wire Length

Recommended Wire Size

1­115 ft (0.3­35 m)

No. 18 AWG

115­185 ft (35­56 m)

No. 16 AWG

185­295 ft (56­89 m)

No. 14 AWG

295­460 ft (89­140 m)

No. 12 AWG

BLACK **

0 – DC (-) Common ground wire

RED ***

194 – DC (+) 12 VDC for transfer controls

WHITE ***

23 – Transfer control signal wire

• Must be connected to keep battery charged whether unit is running or not. ** Required if generator is paired with optional Digital Power Management (DPM) smart technology. *** No connection required in off-grid mode.

30

Installation Guidelines For 60 Hz EcoGenTM Generators

Electrical Connections

Table 6-4. Ground and Neutral Connections (Copper or Aluminum Conductors)

See national and/or local codes to verify correct wire sizes.

No.

Description

Recommended Wire Size

Torque Spec

1

Power wire terminals

2/0 to 8 AWG

120 in-lb (13.56 Nm)

2

Large neutral lug

2/0 to 14 AWG

120 in-lb (13.56 Nm)

3 Large ground lug 2/0 to 14 AWG 120 in-lb (13.56 Nm)

4 Neutral bus bar

4-6 AWG 8 AWG 10-14 AWG

35 in-lb (3.95 Nm) 25 in-lb (2.82 Nm) 20 in-lb (2.26 Nm)

Wire 178
183

Table 6-5. Remote Start Connections

Connection

Location

Mated Fastons Two-Wire Start
Mated Fastons Two-Wire Start

Hanging from controller above battery compartment

Main AC Wiring
NOTE: Main AC wiring must be in accordance with local jurisdiction and codes.
NOTE: Generator lugs are rated at 167 °F (75 °C), copper or aluminum.
1. Strip insulation off wire ends. Do not remove excessive insulation.
2. See Figure 6-1. Loosen lugs at neutral (D), ground (G), and power wire (mains) terminals (E1, E2).
3. Connect ground wire to ground lug and tighten to required specification. See Table 6-4.
4. Connect neutral wire to neutral lug if applicable. Tighten to required specification. See Table 6-4.
5. Insert power wires (E1 and E2) into corresponding lugs. Tighten to required specification.
6. Verify factory-installed ground array and neutral connections are correctly tightened to 25 in-lb (2.82 Nm).
NOTE: Neutral wire must remain connected to keep battery charged whether generator is running or not.
NOTE: Neutral bonding ­ For installations requiring neutral to be bonded to ground, this is done on the customer connections terminals inside generator.

See Figure 6-1. Connect a suitably sized system bonding jumper in accordance with NEC Table 250.102(C)(1) from neutral bar (J) to ground stud (F). Tighten ground stud nut to 35 in-lbs (3.95 Nm). This is required when generator is installed as a separately derived system. Generator will also require a connection to a grounding electrode system in accordance with NEC Article 250.64. It is not required when generator is a backup source in a utility supplied electrical system with a 2-pole transfer switch. Installation must be made in accordance with NEC Articles 250.30 and 250.35(A) if generator will be installed as a separately derived system.
NOTE: 120V loads can be connected across either E1 to Neutral or E2 to Neutral. If running in this 120V configuration, limit load across either connection to 50% of rated load to prevent damage to wires or main line circuit breaker.
NOTE: Tighten all wiring lugs, bus bars, and connection points to required torque specifications.
Conductors of AC and DC circuits, rated 1000 volts nominal or less, shall be permitted to occupy the same equipment, cable, or conduit. All conductors shall have an insulation rating equal to at least the maximum circuit voltage applied to any conductor within the equipment, cable, or conduit. See NEC 300.3(C)(1).

Service Entrance Decals
See Figure 2-7. Locate service entrance-related decals in the loose parts bag.
· Place service disconnect decal next to main line circuit breaker (generator disconnect) (if required by local code).
· Place service entrance warning decal in an appropriate location according to instructions printed on decal.

Common Alarm Relay (Option)
Alarms relating to generator and engine performance appear on the controller and in the Mobile LinkTM application (if used). The controller is equipped with a common alarm relay providing contacts for an optional customersupplied external alarm indicator.
The common alarm relay is normally open until an alarm occurs, triggering relay to close contacts.
Terminals for the common alarm relay are provided in the wiring harness near the controller plug (Wires 209 and 210).
Contact rating is for resistive load only:

Contact rating

200 mA at 12 VDC

Installation Guidelines For 60 Hz EcoGenTM Generators

31

Electrical Connections

Battery Requirements
12 volts, Group 26R Wet Cell 540CCA minimum, or Group 35 AGM 650CCA minimum. If internal battery charger is not connected to utility power, controller will drain the 12VDC battery if not correctly maintained. Total power usage of controller and Wi-Fi module while generator is not running is 2.5 W.
NOTE: A warning is displayed on the LCD when battery needs service.
NOTE: Do not use external battery chargers with OffGrid mode disabled and unit equipped with a transfer switch.
NOTE: With Off-Grid mode enabled and unit equipped with a two-wire start, use an external battery charger to maintain battery if T1 connection is not connected to utility.
Battery Installation

WARNING

Explosion. Batteries emit explosive gases while charging.

Keep fire and spark away. Wear protective gear when

working with batteries. Failure to do so could result in

death or serious injury.

(000137a)

WARNING
Risk of burns. Batteries contain sulfuric acid and can cause severe chemical burns. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury.
(000138a)
· (Group 26R batteries only): Fill battery with correct electrolyte fluid if necessary.
· Fully charge battery before installing it. Complete the following steps before installing and connecting battery:
1. Verify generator is OFF. 2. Turn off utility power supply to transfer switch. 3. Remove 7.5A fuse from generator control panel.
Connecting Battery

WARNING

Explosion. Batteries emit explosive gases.

Always connect positive battery cable first to

avoid spark. Failure to do so could result in

death or serious injury.

(000133)

See Figure 6-2. Battery cables (A, B) were factory connected at the generator.

B

A

­

001832
Figure 6-2. Battery Cable Connections
Connect battery cables to battery posts as follows: 1. Connect red positive battery cable (A: from starter contactor) to positive battery post. Tighten to 70 inlb (8 Nm). 2. Connect black negative battery cable (B: from frame ground) to negative battery post. Tighten to 70 in-lb (8 Nm). 3. Install red battery post cover (shipped with loose parts).
NOTE: Apply dielectric grease to battery posts to prevent corrosion.
NOTE: In areas where temperatures fall below 0 °F (-18 °C), a pad type battery warmer is recommended to aid in cold climate starting. The battery warmer is available as part of a cold weather kit from any IASD.
NOTE: Battery heater and oil heater require N1 and N2 connections to 240V utility. Breather heater requires T1 connection to 120V.
A battery warmer is not necessary for AGM-style batteries.
Battery Disposal
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)
Always recycle batteries in accordance with local laws and regulations. Contact your local solid waste collection site or recycling facility to obtain information on local recycling processes. For more information on battery recycling, visit the Battery Council International website at: http://batterycouncil.org

32

Installation Guidelines For 60 Hz EcoGenTM Generators

Control Panel Startup/Testing
Section 7: Control Panel Startup/Testing

Control Panel Interface
The control panel interface is located under the enclosure lid. Verify both left and right side locks are unlocked before attempting to lift enclosure lid. Open lid as directed in Opening the Lid.
Using the AUTO/MANUAL/OFF Buttons

Button

Description of Operation

AUTO

Activates fully automatic system operation. Automatic operation allows unit to start automatically.

OFF

Shuts down engine and also prevents automatic operation of unit.

MANUAL Cranks and starts generator.

1. The display interface will launch Install Wizard upon first power-up of the generator.
2. Follow on-screen instructions on the generator along with Quick Start Guide supplied with the unit to connect generator to home Wi-Fi network.
3. Wait for on-line authentication of generator activation through connected home Wi-Fi network.
4. Follow on-screen instructions to complete the Install Wizard.
NOTE: See Figure 7-2. If generator screen shows message shown below, press ESC and then ENTER to reset to Install Wizard.
NOT ACTIVATED! XXX (H)

000425
Figure 7-1. Generator Control Panel
Generator Setup
The controller illuminates when battery power is applied to the generator during the installation process. Generator must be activated before it will automatically run in the event of a power outage.
Activation To activate the generator, go to www.activategen.com and follow the instructions. Activation is a simple, one-time process. The generator will not prompt to activate again once the unit is activated, even if the generator battery, fuse, and battery charge circuit (T1) are disconnected.
NOTE: The generator must be connected to the home Wi-Fi network for automatic authentication to be completed successfully. See Wi-Fi manual for more information.
NOTE: If home Wi-Fi network is not available, follow instructions on www.activategen.com.
Proceed as follows after activating generator on-line:

009102
Figure 7-2. Not Activated Screen
NOTE: Generator can only be placed in AUTO mode after completing activation process.
IMPORTANT NOTE: Fuel selector knob must be set to the correct fuel for generator to function correctly.

Installation Guidelines For 60 Hz EcoGenTM Generators

33

Control Panel Startup/Testing Display Reads

Language

–

English +

Enable Wi-Fi?

–

Yes

Activate me (ENT) or ESC to run in manual

To Activate go to www.activategen.com

Troubleshooting

Use arrow keys to scroll to desired language. Press ENTER to select.

Language can be changed later using the EDIT menu.

002227

Use arrow keys to either enable or disable Wi-Fi. If YES, see Wi-Fi manual. If NO, continue.
004498

Press ENTER to begin activation process.

If ESCAPE is pressed instead of ENTER, generator will only run in manual mode (for test purposes) and NOT ACTIVATED will be displayed. Press ESC and then ENTER to reset Install Wizard.

002228

If unit has not been activated, go to www.activategen.com. If unit has been activated, press ESC and then ENTER.
002229

34

Installation Guidelines For 60 Hz EcoGenTM Generators

Display Reads

Control Panel Startup/Testing Troubleshooting

Select Hour (0-23) – 6 +

Activation is complete when this screen is displayed. Follow controller prompts to complete installation.

002231

Cold Smart Start
The Cold Smart Start feature is factory-enabled, and can be disabled in the EDIT menu. Generator will monitor ambient temperature and adjust its warm-up delay accordingly when Cold Smart Start is enabled. If ambient temperature is below a fixed temperature upon startup in AUTO mode (per chart below), generator will warm up for 30 seconds, allowing engine to warm before load is applied. If ambient temperature is at or above fixed temperature, generator will start up with normal warm-up delay of six seconds. See Cold Smart Start section in owner’s manual.

Table 7-1. Cold Smart Start Set Point

Generator Size

15 kW

Fixed Temperature

50 °F (10 °C)

NOTE: Cold Smart Start warmup is only available when off-grid mode is DISABLED.

Setting The Exercise Timer
This off-grid generator is not configurable to run in exercise mode. If an exercise is desired, MANUAL mode may be used if connected loads are prepared to accept electrical output while running. If using MANUAL mode, generator will operate at the rated 3,600 rpm until OFF button is pressed.
NOTE: If using Wi-Fi, Mobile Link application should not be used to initiate exercise mode if user does not wish generator to exercise.
IMPORTANT NOTE: Do not place generator in exercise mode if main line circuit breaker is ON (CLOSED). An unexpected power surge may damage connected equipment such as an inverter.

Before Initial Startup
CAUTION
Engine damage. Verify proper type and quantity of engine oil prior to starting engine. Failure to do so could result in engine damage.
(000135)
NOTE: The unit has been run and tested at the factory prior to being shipped and does not require any type of break-in.
NOTE: The unit comes filled with 5W-30 weight organic oil from the factory. Check oil level and add appropriate viscosity and amount of oil if necessary.
Install Wizard See Figure 7-3. The Install Wizard immediately appears upon initial startup. It allows user to input generator settings. The Install Wizard starts every time AC and DC power are removed and reapplied to generator.
Interconnect System Self Test Feature This controller goes through a system self test at startup, which checks for utility voltage on DC circuits. This check prevents damage if installer incorrectly connected AC utility power sense wires into the DC terminal block. The controller will display a warning message and lock out the generator if utility voltage is detected at the DC terminal block, preventing damage to the controller. Power to controller must be removed to clear this warning. Utility voltage must be turned on and present at the N1 and N2 terminals inside the generator control panel for this test to be performed and pass.
NOTE: All appropriate panels must be in place during any operation of generator. This includes operation by a servicing technician, while conducting troubleshooting procedures.

Installation Guidelines For 60 Hz EcoGenTM Generators

35

Control Panel Startup/Testing
Before starting, complete the following:
1. Verify generator is OFF.
2. Set generator main circuit breaker to OFF (OPEN).
3. Turn OFF all breakers to be powered by generator.
4. Verify auxiliary shutdown switch(es) are CLOSED (I).
5. Check engine crankcase oil level and, if necessary, fill to oil dipstick FULL mark with recommended oil. Do not overfill.
6. Inspect fuel supply. Gaseous fuel lines must have been correctly purged and leak tested in accordance with applicable fuel-gas codes. All fuel shutoff valves in the fuel supply lines must be open.
During initial start up only, generator may exceed normal number of start attempts and experience an “OVERCRANK” fault. This is due to accumulated air in the fuel system during installation. Reset control board by pressing OFF mode button and ENTER button, and restart up to two more times if necessary. If unit fails to start, contact an IASD for assistance.

36

Installation Guidelines For 60 Hz EcoGenTM Generators

37

Installation Guidelines For 60 Hz EcoGenTM Generators

Figure 7-3. Install Wizard Menu Map

Note: If language was previously programmed this goes directly to “Select Hour”

Power Up Unit
FIRMWARE V X.XX HARDWARE V X.XX

Language
+ English + Espanol + Francais + Portuguese –
+ …… –
ENTER

Install Wizard
Defaults to English. Select desired language by scrolling through list.

Setup Wi-Fi? Yes + Yes or No –
No

Follow setup process in
Wi-Fi manual

WIFI Signal XX%

Fuel Selection + NG or LP –

Fuel Selection + NG or LP –

Use UP and DOWN arrows to select fuel type, then press “ENTER”.

ENTER

Cold Smart Start? Å YES or NO Æ

Use UP and DOWN arrows. to select YES or NO. Press ENTER.

Update From: WIFI to Begin ENTER
ESC

SYSTEM

DATE/TIME

Select Hour (0-23)

• – 14 + ENTER

*Holding the Up or Down
arrow button for 2 seconds will speed dial through the selections

WIFI

SUB MENUS

+ UP ARROW =

– DOWN ARROW =

ENTER

Cold Smart Start? Å YES or NO Æ
ENTER

ENTER

Time Zone XXXXXX

WIFI Signal XX%
ENTER
Update From Server Continue? ENTER
Controller X.XX.XXX Server X.XX.XXX

Control Panel Startup/Testing

Control Panel Startup/Testing

38

Figure 7-4. Install Wizard Menu Map

ENTER

Select Minute (0-59) ENTER

• – 0 +

Select Month (1-12) ENTER

• – 2 +

Select Date (1-31) ENTER

• – 13 +

SYSTEM

DATE/TIME

SETUP WIFI SUB MENUS

ENTER

ESC USB Only­No WiFi to Begin
ENTER

ENTER

Select Year (0-99)

• – 13 +

ENTER

Switched to OFF Hours of Protection
0 (H)
Possible Message(s): Corrupted File Invalid File File Not Found
Unsupported Device*

• Re-try using a higher quality USB drive. File names on the USB cannot have more than 8 characters.

Firmware Update <- Insert USB ->

ENTER

Current: V X.XX USB: X.XX

ENTER

Are You Sure? – Yes or No +
ENTER

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.

Installation Guidelines For 60 Hz EcoGenTM Generators

008647

Control Panel Startup/Testing

Check Manual Transfer Switch Operation
DANGER
Electrocution. High voltage is present at transfer switch and terminals. Contact with live terminals will result in death or serious injury.
(000129)
If installed with a transfer switch, see Manual Transfer Operation section of owner’s manual for operating procedures.
Electrical Checks
DANGER
Electrocution. High voltage is present at transfer switch and terminals. Contact with live terminals will result in death or serious injury.
(000129)
Proceed as follows to complete electrical checks if unit is equipped with a transfer switch, and with off-grid mode DISABLED:
1. Verify generator is OFF. 2. Set generator main line circuit breaker (generator
disconnect) to OFF (OPEN). 3. Turn off all circuit breakers/electrical loads to be
powered by generator. 4. Turn on utility power supply to transfer switch using
the means provided (such as a utility main line circuit breaker). 5. Use a calibrated AC voltmeter to verify utility power source voltage across transfer switch terminals N1 and N2. Nominal line-to-line voltage should be 240 volts AC. If voltage is incorrect, verify AC output and wiring from utility source to N1 and N2 lugs at transfer switch. 6. Verify utility power source voltage across terminals N1 and transfer switch neutral lug; then across terminal N2 and neutral. Nominal line-to-neutral voltage should be 120 volts AC (if wired with a neutral). If voltage is incorrect, verify AC output and wiring from utility source to N1 and N2 lugs at transfer switch. 7. Turn off utility power supply to transfer switch when utility supply voltage is verified to meet specification provided in Step 6. 8. Press MANUAL mode button on generator panel. Engine will crank and start. Record cranking fuel pressure: __. 9. Allow engine to warm up for approximately five minutes for internal temperatures to stabilize. Then set generator MLCB (generator disconnect) to ON
Installation Guidelines For 60 Hz EcoGenTM Generators

(CLOSED). Record running fuel pressure: __.
10. Connect a calibrated accurate AC voltmeter and a frequency meter across transfer switch terminal lugs E1 and E2. Voltage should be 238­242V at a frequency of 59.5­60.5 Hz. If voltage is incorrect, verify generator main line circuit breaker (generator disconnect) is closed and verify AC output and frequency (Hertz or Hz) at generator main line circuit breaker (generator disconnect). Verify wiring from generator to E1 and E2 lugs at transfer switch.
11. Connect AC voltmeter test leads across terminal lugs E1 and neutral, then across E2 and neutral (if wired with a neutral). In both cases, voltage reading should be 119­121 volts AC. If voltage is incorrect, verify generator main line circuit breaker (generator disconnect) is closed and verify AC output between E1 and E2 of the generator main line circuit breaker (generator disconnect) and neutral at the generator.
12. Verify wiring from generator to E1, E2, and neutral lugs at transfer switch.
13. Set generator main line circuit breaker (generator disconnect) to OFF (OPEN).
14. Press generator OFF mode button. Engine will shut down.
Proceed as follows to complete electrical checks if unit is configured to run without a transfer switch and with offgrid mode ENABLED:
1. Verify generator is OFF.
2. Set generator main line circuit breaker (generator disconnect) to OFF (OPEN).
3. Turn off all circuit breakers and electrical loads to be powered by generator.
4. Press MANUAL mode button on generator panel. Engine will crank and start. Record cranking fuel pressure:____.
5. Allow engine to warm up for approximately five minutes to allow internal temperatures to stabilize. Set generator MLCB (generator disconnect) to ON (CLOSED). Record running fuel pressure: ____.
6. Connect AC voltmeter test leads across terminal lugs E1 and neutral, then across E2 and neutral (if wired with a neutral). In both cases, voltage reading should be 119­121 volts AC. If voltage is incorrect, verify generator main line circuit breaker (generator disconnect) is ON (CLOSED) and verify AC output between E1 and E2 of generator main line circuit breaker (generator disconnect) and neutral at the generator.
IMPORTANT NOTE: Do not proceed until generator AC voltage and frequency are correct and within stated limits.
39

Control Panel Startup/Testing

Generator Tests Under Load
DANGER
Electrocution. Do not manually transfer under load. Disconnect transfer switch from all power sources prior to manual transfer. Failure to do so will result in death or serious injury, and equipment damage.
(000132)
Proceed as follows to test unit with electrical loads applied when unit is equipped with a transfer switch and with off-grid mode DISABLED:
1. Verify generator is OFF. Set generator main line circuit breaker (generator disconnect) to OFF (OPEN).
2. Turn off all breakers/electrical loads to be powered by generator.
3. Turn off utility power supply to transfer switch, using the means provided (such as a main line utility breaker).
4. Manually set transfer switch to STANDBY, with load terminals connected to generator E1/E2 terminals. Transfer switch operating lever should be down.
5. Push generator MANUAL button. Engine will crank and start immediately.
6. Verify fuel pressure while cranking. Record cranking fuel pressure:____
7. Allow engine to stabilize and warm up for a few minutes.
8. Verify fuel pressure while running. Record running fuel pressure:____
9. Set generator main line circuit breaker (generator disconnect) to ON (CLOSED). Loads are now powered by standby generator.
10. Turn on circuit breakers/electrical loads to be powered by generator one by one.
11. Connect a calibrated AC voltmeter and a frequency meter across terminal lugs E1 and E2. Voltage should be approximately 240 volts and frequency should be approximately 60 Hz. If voltage and frequency are rapidly dropping as loads are applied, generator may be overloading, or there may be a fuel issue. Verify output current measurement of loads and/or fuel pressure.
12. Allow generator to run at full rated load for 20­30 minutes. Listen for unusual noises, vibration, or other indications of abnormal operation. Inspect for oil leaks, evidence of overheating, etc.
13. Verify fuel pressure while under full load. Record loaded fuel pressure: __.
14. Turn off electrical loads when testing under load is complete.
15. Set generator main line circuit breaker (generator disconnect) to OFF (OPEN).
40

16. Allow engine to run at no-load for 2­5 minutes. 17. Press generator OFF mode button. Engine will
shut down.
Proceed as follows to test unit with electrical loads applied when unit is configured to run without a transfer switch and with off-grid mode ENABLED:
1. Verify generator is OFF. Set generator main line circuit breaker (generator disconnect) to OFF (OPEN).
2. Turn off all breakers/electrical loads to be powered by generator.
3. Press MANUAL mode button on generator panel. Engine will crank and start.
4. Verify fuel pressure while cranking. Record cranking fuel pressure:_____.
5. Allow engine to stabilize and warm up for a few minutes.
6. Set generator main line circuit breaker (generator disconnect) to ON (CLOSED). Loads are now powered by standby generator.
7. Turn on circuit breakers and electrical loads to be powered by generator one by one.
8. Connect a calibrated AC voltmeter and a frequency meter across terminal lugs E1 and E2. Voltage should be approximately 240 volts and frequency should be approximately 60 Hz. If voltage and frequency are rapidly dropping as loads are applied, generator may be overloading, or there may be a fuel issue. Verify output current measurement of loads and/or fuel pressure.
9. Allow generator to run at full rated load for 20­30 minutes. Listen for unusual noises, vibration, or other indications of abnormal operation. Inspect for oil leaks, evidence of overheating, etc.
10. Verify fuel pressure while under full load. Record loaded fuel pressure: __.
11. Turn off electrical loads when testing under load is complete.
12. Set generator main line circuit breaker (generator disconnect) to OFF (OPEN).
13. Allow engine run at no-load for 2­5 minutes. 14. Press generator OFF mode button. Engine will
shut down.
NOTE: If fuel pressure under full load is below minimum operating pressure guideline, generator may not function correctly. Fuel pressure gauge needle should also remain steady while testing. A fluctuating fuel pressure gauge needle indicates gas piping may be undersized or restricted. It may also indicate a step-down gas regulator is too small, or too close to the unit.
Installation Guidelines For 60 Hz EcoGenTM Generators

Control Panel Startup/Testing

Checking Automatic Operation
Proceed as follows to check system for correct automatic operation when unit is equipped with a transfer switch and with off-grid mode DISABLED:
1. Verify generator is OFF.
2. Install front cover of transfer switch.
3. Turn on utility power supply to transfer switch using the means provided (such as a utility MLCB).
NOTE: Transfer switch will transfer to utility position.
4. Set generator main line circuit breaker (generator disconnect) to ON (CLOSED).
5. Press generator AUTO button. System is now ready for automatic operation.
6. Turn off utility power supply to transfer switch.
Generator is ready for automatic operation. Engine will crank and start when utility power source is turned off after a five second delay (factory default setting). After starting, transfer switch will connect load circuits to the standby side after a 5 or 30 second delay (dealer programmable). See Cold Smart Start. Allow system to operate through entire automatic sequence of operation.
With generator running and loads powered by generator AC output, turn on utility power supply to transfer switch. The following will occur:
· After approximately 15 seconds (dealer programmable), transfer switch will transfer loads to utility power source.
· Approximately one minute after transfer, engine will shut down.
Proceed as follows to check the system for correct automatic operation when configured to run without a transfer switch and with off-grid mode ENABLED:
1. Verify generator is OFF.
2. Press AUTO mode button. System is now ready for automatic operation.
3. Verify remote two-wire start test switch installed near the Alternative Power Management System is set to ON (CLOSED). This causes generator to start automatically.
4. With generator running and powering loads, set remote two-wire start test switch to OFF (OPEN). Generator will shut down immediately (selectable to one minute in the dealer menu) after two-wire remote start signal is OFF (OPEN).

3. Educate end-user on correct operation, maintenance, and service call procedures.
Shutting Generator Down While Under Load or During a Utility Outage
DANGER
Automatic start-up. Disconnect utility power and render unit inoperable before working on unit. Failure to do so will result in death or serious injury.
(000191)
IMPORTANT NOTE: To avoid equipment damage, follow these steps, in order, during utility outages. Shutdowns may be required during utility outages to perform routine maintenance or to conserve fuel.
To turn generator OFF: 1. Set main utility disconnect to OFF (OPEN). 2. Set generator MLCB (generator disconnect) to OFF (OPEN). 3. Allow generator to run for cool-down for approximately one minute. 4. Set generator to OFF at the controller. 5. Remove 7.5A fuse from controller.
To turn generator back ON: 1. Install 7.5A fuse in controller. 2. Verify generator MLCB (generator disconnect) is OFF (OPEN). 3. Set generator to AUTO mode at the controller. 4. Generator will start and run. Allow generator to run and warm up for a few minutes. 5. Set MLCB (generator disconnect) to ON (CLOSED). 6. Set main utility disconnect to ON (CLOSED).
The system now operates in automatic mode.

Installation Summary
1. Verify installation has been performed correctly as outlined by the manufacturer and that it meets all applicable laws and codes.
2. Test and verify correct operation of the system as outlined in the appropriate installation and owner’s manuals.

Installation Guidelines For 60 Hz EcoGenTM Generators

41

Control Panel Startup/Testing
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42

Installation Guidelines For 60 Hz EcoGenTM Generators

Section 8: Troubleshooting

Troubleshooting

Generator Troubleshooting

Problem

Cause

Blown fuse.

Engine will not crank

Loose, corroded, or faulty battery cables. Faulty starter contact.

Faulty starter motor.

Discharged battery.

No fuel.

High fuel pressure.

Fuel selector in wrong position.

Engine cranks but

will not start

Faulty fuel solenoid (FS).

Faulty spark plug(s).

Valve clearance out of adjustment. Air cleaner clogged or damaged. Faulty spark plug(s).

Engine starts hard Incorrect fuel pressure. and runs rough

Generator is set to OFF, but engine continues to run
No AC output from generator

Fuel selector in wrong position. Valve(s) out of adjustment. Internal engine issue. Controller wired incorrectly.
Faulty control board.
Main line circuit breaker (MLCB) (generator disconnect) is OFF (OPEN). Generator internal failure. Engine may be warming up. See Cold Smart Start.

Correction Correct short circuit condition by replacing 7.5 A fuse in generator control panel. Contact an IASD if fuse continues to blow.
Tighten, clean, or replace as necessary.*
Charge or replace battery. Replenish fuel / turn on fuel valve. Check and adjust fuel pressure. Set fuel conversion valve to correct position. Replenish fuel / turn on fuel valve. Clean; inspect gap; replace plug(s) if necessary. Reset valve clearance. Inspect and clean air cleaner. Clean; inspect gap; replace plug(s) as needed. Verify fuel pressure to regulator is 10­12 in water column (2.49­2.99 kPa) for LP gas, and 3.5­7.0 in water column (0.87­1.74 kPa) for NG. Set fuel conversion valve to correct position. Adjust valve clearance. Contact an IASD for assistance.
Contact an IASD for assistance.
Reset generator disconnect to ON (CLOSED).
Contact an IASD for assistance.
Check controller screen to verify status.

Installation Guidelines For 60 Hz EcoGenTM Generators

43

Troubleshooting

Problem

Cause

Correction

MLCB (generator disconnect) is OFF (OPEN). Reset generator disconnect to ON (CLOSED).

No transfer to standby after utility source failure **

Faulty transfer switch coil. Faulty transfer relay. Transfer relay circuit open. Faulty control logic board.

Contact an IASD for assistance.

Engine may be warming up. See Cold Smart Start.

Check controller screen to verify status.

Excessive engine oil.

Adjust oil to correct level.

Unit consumes large amounts of oil

Faulty engine breather. Incorrect type or viscosity of oil. Damaged gasket, seal, or hose.

Contact an IASD for assistance.
See Engine Oil Requirements in owner’s manual.
Inspect for oil leaks.

Restricted air filter.

Replace air filter.

Wi-Fi network connection broken or intermittent

Various.

See Wi-Fi module owner’s manual.

• Contact an IASD or visit www.generac.com for assistance. ** Not applicable with Off-Grid mode ENABLED.

44

Installation Guidelines For 60 Hz EcoGenTM Generators

Section 9: Quick Reference Guide

Quick Reference Guide

System Diagnosis
To clear an active alarm, press OFF mode button on control panel, then ENTER button. Then press AUTO mode button. Contact an IASD if alarm reoccurs.

Active Alarm LED

Problem

Things to Check

Solution

NONE

FLASHING Unit running in AUTO but

GREEN

no power in house.

Check MLCB (generator disconnect).

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

HIGH TEMPERATURE

RED

Unit shuts down during operation.

Check LED’s / Screen for alarms.

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

OVERLOAD REMOVE LOAD

RED

Unit shuts down during operation.

Check LED’s / Screen for alarms.

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

RPM SENSE LOSS RED

Unit was running and shuts down, attempts to
restart.

Check LED’s / Screen for alarms.

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

NOT ACTIVATED

NONE

Unit will not start in AUTO with utility loss.

Verify if screen says unit not activated.

See Activation section in owner’s manual.

NONE

GREEN

Unit will not start in AUTO with utility loss.

Check screen for start delay countdown.

If startup delay is greater than expected, contact an IASD to adjust between 2 to 1500 seconds.

LOW OIL PRESSURE

RED

Unit will not start in Check LED’s / Screen Check oil level and add oil as needed. If oil

AUTO with utility loss.

for alarms.

level is correct, contact an IASD.

RPM SENSE LOSS RED

Unit will not start in AUTO with utility loss.

Check LED’s / Screen for alarms.

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

OVERCRANK

RED

Unit will not start in AUTO with utility loss.

Check LED’s / Screen for alarms.

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

LOW VOLTS REMOVE LOAD

RED

Unit will not start in Check LED’s / Screen Clear alarm and remove household loads

AUTO with utility loss.

for alarms.

from generator. Put into AUTO and restart.

OVERSPEED

RED

Unit will not start in AUTO with utility loss.

Check LED’s / Screen for alarms.

Contact an IASD.

UNDERVOLTAGE

RED

Unit will not start in AUTO with utility loss.

Check LED’s / Screen for alarms.

Contact an IASD.

UNDERSPEED

RED

Unit will not start in AUTO with utility loss.

Check LED’s / Screen for alarms.

Contact an IASD.

STEPPER OVERCURRENT

RED

Unit will not start in AUTO with utility loss.

Check LED’s / Screen for alarms.

Contact an IASD.

MISWIRE

RED

Unit will not start in AUTO with utility loss.

Check LED’s / Screen for alarms.

Contact an IASD.

Installation Guidelines For 60 Hz EcoGenTM Generators

45

Quick Reference Guide

Active Alarm LED

Problem

Things to Check

Solution

OVERVOLTAGE

RED

Unit will not start in AUTO with utility loss.

Check LED’s / Screen for alarms.

Contact an IASD.

AUXILIARY SHUTDOWN

RED

Unit will not start.

Check auxiliary Set auxiliary shutdown switch(es) to shutdown switch(es). CLOSED (I).

LOW BATTERY

YELLOW

Yellow LED illuminated in any state.

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

BATTERY PROBLEM

YELLOW

Yellow LED illuminated in any state.

Check screen for additional information.

Contact an IASD.

CHARGER WARNING

YELLOW

Yellow LED illuminated in any state.

Check screen for additional information.

Contact an IASD.

CHARGER MISSING AC

YELLOW

Yellow LED illuminated in any state.

Check screen for additional information.

Contact an IASD.

SERVICE A

YELLOW

Yellow LED illuminated in any state.

Check screen for Perform SERVICE A maintenance. Press additional information. ENTER to clear.

SERVICE B

YELLOW

Yellow LED illuminated in any state.

Check screen for Perform SERVICE B maintenance. Press additional information. ENTER to clear.

INSPECT BATTERY

YELLOW

Yellow LED illuminated in any state.

Check screen for additional information.

Inspect battery. Press ENTER to clear.

46

Installation Guidelines For 60 Hz EcoGenTM Generators

Section 10: Accessories

Accessories

Performance enhancing accessories are available for air-cooled generators.

Accessory Cold Weather Accessories–
· Battery Pad Warmer · Oil Warmer · Breather Warmer each sold separately Scheduled Maintenance Kit
Fascia Base Wrap
Touch-Up Paint Kit
Wi-Fi LP Fuel Level Monitor

Description
· Recommended in areas where temperatures fall below 0 °F (-18 °C). (Not necessary for use with AGM-style batteries)
· Recommended in areas where temperatures fall below 0 °F (-18 °C). · Recommended in areas where heavy icing occurs.
Includes all pieces necessary to perform maintenance on the generator along with oil recommendations.
The fascia base wrap snaps together around the bottom of the new air-cooled generators. This offers a sleek, contoured appearance as well as offering protection from rodents and insects by covering the lifting holes located in the base. Requires use of the mounting pad shipped with the generator.
Very important to maintain the look and integrity of the generator enclosure. This kit includes touch-up paint and instructions.
The Wi-Fi enabled LP fuel level monitor provides constant monitoring of the connected LP fuel tank. Monitoring the LP tank’s level is an important step in making sure your generator is ready to run during an unexpected power failure. Status alerts are available through the Mobile Link application informing you when your LP tank needs a refill.

NOTE: Contact an IASD or visit www.generac.com for additional information on accessories and extended warranties.

Installation Guidelines For 60 Hz EcoGenTM Generators

47

Accessories
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48

Installation Guidelines For 60 Hz EcoGenTM Generators

Section 11: Diagrams
Installation Drawing (10000037315 rev A–1 of 2)

Diagrams

MOUNTING TO CONCRETE PAD

HOLE LOCATIONS FOR OPTIONAL MOUNTING TO
A CONCRETE PAD
16 [5/8] DIA. CLEARANCE HOLE (3) PLACES,
10 [3/8] DIA. MASONRY ANCHOR BOLTS RECOMMENDED

FRONT OF UNIT

19.7 [7.7] 457 [18.0]

393 [15.5]

521 [20.5] 68 [2.7]

( ) MAIN AC/CONTROL WIRING HOLE FOR 1 1/4″ CONDUIT MAIN AC/CONTROL WIRING HOLE FOR 3/4″ CONDUIT

-REMOVE FACTORY PLUGS AND DISCARD -CLOSE ANY UNUSED HOLE WITH A NEMA 3R RATED PLUG (FIELD SUPPLIED)

AUXILIARY SHUTDOWN SWITCH

WIRELESS MODULE

FUEL INLET : 1/2″ NPT REQUIRED FUEL PRESSURE : NATURAL GAS : 3.5-7″ WATER COLUMN
LIQUID PROPANE (VAPOR) : 10-12″ WATER COLUMN

635 [25.0]

345 [13.6] 218 [8.6]

REAR VIEW

Installation Guidelines For 60 Hz EcoGenTM Generators

733 [28.8] 648 [25.5] LEFT SIDE VIEW
49

Diagrams Installation Drawing (10000037315 rev B–2 of 2)

914 [36.0] MINIMUM OPEN AREA

AIR INTAKE

457 [18.0] MINIMUM OPEN AREA

AIR OUTLET
“DO NOT LIFT BY ROOF”

TOP VIEW
914 [36.0] MINIMUM OPEN AREA

AIR INTAKE
914 [36.0] MINIMUM OPEN AREA

LIFTING HOLES 4 CORNERS: 30 [ 1.2] – MUST BE LIFTED WITH STEEL RODS – RECOMMENDED LIFTING ROD SIZE: 25 [ 1.0] 1218 [48.0]

RIGHT VIEW INTAKE PANEL REMOVED

127 [5.0] GRAVEL PAD/ COMPACTED SOIL
50

1232 [48.5] FRONT VIEW

RIGHT SIDE VIEW
TITLE
INSTALL HSB GENERATOR ECOGEN WM
Installation Guidelines For 60 Hz EcoGenTM Generators

51

Installation Guidelines For 60 Hz EcoGenTM Generators

120V/240V CHARGER
SUPPLY

ECOGEN – TYPICAL OFF-GRID APPLICATION SYSTEM DIAGRAM

TWO-WIRE START

ENGINE CONTROLLER

GENERATOR

12 VOLT ENGINE START BATTERY
ENGINE START BATTERY CHARGER
TWO-WIRE START

120/240V OUTPUT
ALTERNATOR

HOUSE LOADS*

AC DISTRIBUTION
PANEL 120/240V

INVERTER

TWO-WIRE START
BATTERY VOLTAGE SENSING

BATTERY CHARGER

INVERTER/CHARGER

HOUSE LOADS*

DC DISTRIBUTION
PANEL 12V/24V/48V

BATTERY 12V/24V/48V

*House Loads must be less than 10 kW or 2 hp

HOUSE

PHOTO VOLTAIC PANEL

24/48V DC
12/24/36/48V DC
WIND TURBINE
008705

Off-Grid Mode Application Schematic

Diagrams

Installation Guidelines For 60 Hz EcoGenTM Generators

52

VENT HOSE

OIL MAKE UP SYSTEM SCHEMATIC
(NOT TO SCALE)

OIL DIPSTICK AND FILL

ENGINE-IN HOSE (TO OIL PUMP)
ENGINE-OUT HOSE

008706

Diagrams
Oil Make Up System Schematic

Diagrams
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Installation Guidelines For 60 Hz EcoGenTM Generators

53

Diagrams
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54

Installation Guidelines For 60 Hz EcoGenTM Generators

Part No. 10000032205 Rev. B 12/17/2018 ©2018 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) www.generac.com

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