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PIB14-04-AG

PRODUCT INFORMATION BULLETIN DATE: February 2014 (Rev. B) SUBJECT: Air-Cooled Evolution Controller Firmware MODELS AFFECTED: All Air-Cooled Evolution Controlled Generators PROBLEM: Procedures for downloading firmware from GenService, initiating/formatting the Flash Drive, downloading the firmware file to the Flash Drive, and downloading the firmware into the Evolution Controller. WARRANTY: Information Only CORRECTIVE ACTION: Important Note: This is an example scenario only!

Only the SanDisk Ultra Backup™ 8GB and Verbatim Store ‘n’ Go™ 8GB Flash Drives have been tested and should be used. Generac does not supply these flash drives. They are to be obtained locally through any computer or online retail store. 1. Log into GenService. 2. Click on the “Documentation” tab. 3. Click on “Service Documents”.

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PIB14-04-AG 4. On the left side of the display, click on “+ Evolution Firmware AC/LC” to open folder. 5. Click on “Air-Cooled Evolution Firmware Upgrade Version 1.07”.

6. Click on blue “Document”.

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PIB14-04-AG 7. Click on “Open”.

8. This will open as a .zip file.

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PIB14-04-AG 9. Click once to highlight the “AC Evolution Firmware” folder.

Do not double click or open the firmware file. Doing so may corrupt it!

10. Click on “Extract”.

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PIB14-04-AG 11. Copy to: “Desktop” and click on “OK”. A folder called “AC Evolution Firmware” will be on your Desktop.

12. Initiating the Flash Drive • Components Needed: Computer and qualified Flash Drive • Insert the Flash Drive into a USB port of the computer. When installing the Flash Drive to your computer, it will go through the initialization of the drivers for the new Flash Drive.

• Once the drivers have been loaded and your system recognizes the drive, you need to format the new Flash Drive to insure compatibility and Firmware update operation. • Depending on the operating system for your computer, locate the recently attached Flash Drive (see the example below).

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PIB14-04-AG 13. Right click on the drive. This brings up a sub menu shown below. Select “Format”.

14. The Format menu will appear. Be sure the File System “FAT32” is selected.

15. With the correct File System selected, select” Start” to begin the process. NOTE: A warning will display. Select “OK” when ready.

16. Once the format is completed select “Close” on the Format screen. The Flash Drive is now correctly formatted and ready for file transferring. 17. Click on and open the folder “AC Evolution Firmware” on the desktop.

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PIB14-04-AG 18. Click once to highlight the file and right click your mouse and “Copy”.

Do not double click or open the firmware file. Doing so may corrupt it!

19. Paste the “Evo-gen” firmware file into the empty Flash Drive and acknowledge that the file is now on the Flash Drive.

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PIB14-04-AG

20. Eject the Flash Drive. 21. The Flash Drive is now ready to download the firmware upgrade into the Air-Cooled Evolution controller. 22. Use the attached Evolution Menu Map to download the Firmware Upgrade into the Evolution controller. After the Firmware update follow the “Install Wizard” to insure correct fuel, time and date etc. on the unit. Simulate a power outage to insure system is operating correctly. Important Note: The Blue "Manual" light will flash, then the Green "Auto" light flashes. It does this once for firmware (single file), and twice for firmware and hardware (two files).

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PIB14-04-AG AIR-COOLED EVOLUTION BOOTLOADER TROUBLE SHOOTING NOTE: There are three notification LEDs on User Interface (Auto = Green, Manual = Blue, Off = Red). The User Run notification is the Blue LED.

Problem • Power Up/Reboot • Flashing User Run Notification LED • CONTROLLER DOES NOT RUN

Correction The Bootcode has detected that there is no application or the application is corrupted. The User Run Notification flashing LED is a signal that it cannot proceed with the boot process and it is looking for an application to download. Use the recommended USB flash drive and place a valid “Evo.gen” file in the root directory. Insert it into the controllers USB port and watch for the green LED to flash which indicates the download process has begun.

• Power Up/Reboot – USB Inserted • Flashing User Run Notification LED

If a USB device with the “Evo.gen” file is inserted, the “Evo.gen” file might be misnamed or not in the root directory.

• CONTROLLER DOES NOT RUN • Power Up/Reboot – USB Inserted – w/ “Evo.gen” file • Flashing User Run Notification LED – Followed by flashing Green • CONTROLLER DOES NOT RUN

The Bootcode has found the “Evo.gen” file on the stick and has validated it. After downloading the file to the unit, it has detected that the file is corrupt and will not proceed with the boot process and continues to look for an application to download. This is only possible if the flash memory in the controller is defective and the unit cannot be programmed. Replace the controller.

• Repeats • Power Up/Reboot – USB Inserted – w/ “Evo.gen” file • Flashing User Run Notification LED • Flashing Red LED • CONTROLLER DOES NOT RUN

The Bootcode has found the “Evo.gen” file on the stick and has determined that there is a problem with it. It has also detected that there is no application or the application is corrupted in flash. 1. Try reinserting the USB flash drive. 2. Try recopying the file to the USB flash drive. 3. Try using another USB flash drive with a fresh copy of the file. OR The “Evo.gen” file might be fine, but the USB device being used might be unsupported. Use the recommended USB flash drive.

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PIB14-04-AG • Power Up/Reboot – USB Inserted – w/ “Evo.gen” file • Flashing User Run Notification LED • Flashing Red LED • CONTROLLER RUNS OLD APPLICATION • Attempt download of “Evo.gen” file • OLD APPLICATION SHOWS “Invalid File” MESSAGE

The Bootcode has found the “Evo.gen” file on the flash drive and has determined that there is a problem with it. It has also determined that the application on the unit is still valid and continues the boot process so the unit can run. The problem that the Bootcode has seen should be reported by the application for a few seconds at the start of the application. The “Evo.gen” file doesn’t have the proper identification in the file and is rejected by the Bootcode. Perhaps the file was renamed? Obtain the recommended USB flash drive and place a valid “Evo.gen” file in the root directory. Insert it into the controllers USB port and watch for the green LED to flash which indicates the download process has begun.

• Attempt download of “Evo.gen” file • OLD APPLICATION SHOWS “Corrupted File” MESSAGE

The “Evo.gen” file was CRC tested and it failed. The file has been altered in some way. Obtain the recommended USB flash drive and place a valid “Evo.gen” file in the root directory. Insert it into the controllers USB port and watch for the green LED to flash which indicates the download process has begun.

• Attempt download of “Evo.gen” file • OLD APPLICATION SHOWS “Unsupported Device” MESSAGE

The USB device was recognized, but the Bootcode wasn’t able to properly use it. It may have drawn too much current. Obtain the recommended USB flash drive and place a valid “Evo.gen” file in the root directory. Insert it into the controllers USB port and watch for the green LED to flash which indicates the download process has begun.

• Attempt download of “Evo.gen” file • OLD APPLICATION SHOWS “Unsupported Device” MESSAGE • CONTROLLER APPEARS TO “LOCK UP” FOR AWHILE • Using Evolution Serial Download Tool • Attempt selection of “Evo.gen” file • TOOL REPORTS AN ERROR WITH THE FILE • Attempt download of “Evo.gen” file – Know file is valid • CONTROLLER RUNS OLD APPLICATION

The over current “software fuse” has been tripped. It resets at about 50 seconds. Remove the device from the USB port and wait, or navigate out of the USB menus and back in to reset. Do not use unsupported device! Make sure a “Evo.gen” is being selected and not a hex file. It’s also possible that the file has become corrupted in some way. Obtain the recommended USB flash drive and place a valid “Evo.gen” file in the root directory. Make sure there is only one file in the root directory of the flash drive. If it takes too long to find the “Evo.gen” file, the boot process can time out and will jump to the already loaded code.

Internal Use Only - Not For Distribution

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Switched to “OFF” Hours of Protection 0 (H)

2013 EVOLUTION/SYNC2.0 HSB MENU MAP

Current Date/Time 02/14/13 07:40

ESC

Running Manual Running-Utility Lost Running-Remote Start Running-2 Wire Start Running - Exercise Switched Off Stopped - Auto Stopped - Alarm

SYSTEM

ENTER

Battery Condition

BATTERY

ESC

ENTER

- 1 thru 50 +

ESC

- 1 thru 50 +

Warning Message(s) "Low Battery" "Exercise Set Error" "FIRMWARE ERROR-9" "Fuel Pressure" "Battery Problem" "Charger Warning" "Charger Missing AC" "Overload Warning" "Overload Cooldown" "SEEPROM ABUSE" "USB Warning" "Download Failure"

Alarm Message(s) "High Engine Temp." "Low Oil Pressure" "Overcrank" "Overspeed" "RPM Sense Loss" "Underspeed" "Internal Fault" "FIRMWARE ERROR-7" "WIRING ERROR" "Over Voltage" "Under Voltage" "Overload Remove Load" "Low Volts Remove Load" "Stepper Over Current" "Fuse Problem"

0198170GST-E 02/20/14 Page 1 of 4

ENTER

- Run Log +

ENTER

“Run Log”

ESC

- Alarm Log +

ENTER

ESC

MAINT

EDIT

MAINT:

ESC ENTER

DEALER

ENTER

ESC



English



ENTER

ESC

ESC



ENTER

Language

+

Language

+

Language

+

Language

+ English -

-

+ Espanol -

-

+ Francais -

-

+ Portuguese -

Current Date/Time 2/12/13 12:22



Select Hour (0-23)

ENTER

ENTER

- 14 +



Exercise Time 

Quiet Test Mode ?

ENTER

14:00 Wednesday

- YES or NO +



ESC

ESC

Select Min (0-59)

ENTER

- 2 +

ESC ENTER

Select Hour (0-23)

ENTER

Firmware Update 

Press Enter

and Next Maintenance 200 RnHr or 12/27/13

Select Min (0-59)

- 14 +



ENTER ESC

Firmware Update 

Insert USB



ESC ENTER

- 13 +

ESC ENTER

Select Date (1-31)

ESC

ENTER

Select Year (0-99) - 13 +

ENTER

Select Day

ENTER

- 0 +

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

Quiet Test Mode only on certain models

ESC

EXAMPLE: Inspect Battery 200 RnHr or 12/27/13

ESC

Select Month (1-12)

- 0 +

ESC ESC

+

ESC

+ NG or LP -

NG or LP 

ESC ESC

- 1 thru 50 + "Battery Maintained" "Schedule A Serviced" "Schedule B Serviced" "Maintenance Reset" "Inspect Battery" "Service Schedule A" "Service Schedule B"

ESC

Fuel Selection

ENTER

Fuel Selection

Scheduled

Maint. Log

Access Requires Password

ENTER

Run Hrs

ENTER

Language

DOWN ARROW =

0.0

ESC

HISTORY

ESC

“Alarm Log”

ENTER

ENTER

SUB MENUS

ENTER

Possible Message(s) Corrupted File Invalid File File Not Found Unsupported Device

+

ESC

DATE/TIME

Run Hours (H)

ENTER

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

UP ARROW =

"Current:V XXXX " "USB:

V XXXX"

ENTER ESC

"Are You Sure?" "- Yes or No +"

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.

-

2013 EVOLUTION/SYNC 2.0 HSB ACTIVATION AND INSTALL WIZARD MENU MAP Power Up Unit

FIRMWARE V 1.01

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

ESC

Activate me (ENT) or ESC to run in MANUAL

UP ARROW =

HARDWARE V 1.05

Fuel Selection

Non Activated Unit

+

Install Wizard

+ NG or LP -

DOWN ARROW =

-

ENTER

Activated Unit

To activate go to www.activategen.com

Note: If language was previously programmed this goes directly to “Select Hour” Serial 1234567890 PASSCODE xxxxx Use up and down arrows to change selection 0 thru 9. Press "Enter" to acccept selection and to move to the next digit. If passcode is correct goes to "Install Wizard." If not correct goes to the message below.

Language

+

Language

+

Language

+

Language

+

Language

+

+ _______ -

-

+ English -

-

+ Espanol -

-

+ Francais -

-

+ Portuguese -

ENTER

Defaults to English if not selected.

Select Hour (0-23) - 14 +

Wrong Passcode Try Again

ENTER

Select Min (0-59) - 0 +

*

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

ENTER

Select Month (1-12) - 2 +

*

ENTER

Select Date (1-31) - 13 +

*

ENTER

Select Year (0-99) - 13 +

*

*

Non Activated Unit

“NOT ACTIVATED!” Hours of Protection 0 (H) To return to Activation Screen disconnect battery and AC power to restart controller

Install Wizard Set Exercise

ENTER

Quiet Test Mode ? - YES or NO +

ENTER

Select Hour (0-23) - 14 +

Quiet Test Mode only on certain models Switched to “OFF” Hours of Protection 0 (H)

0198170GST-E 02/20/14 Page 2 of 4

ENTER

Select Min (0-59) - 0 +

* ENTER

SYSTEM

BATTERY

ENTER

Select Day - Wednesday +

* DATE/TIME

SUB MENUS

*

2013 EVOLUTION/SYNC 2.0 HSB FIRMWARE MENU MAP

Switched to “OFF” Hours of Protection 0 (H)

ESC

Alternate Firmware Update Method: ENTER

Control unit at main screen and Insert Thumb drive with Firmware

SYSTEM

DATE/TIME

Power the unit down completely. Disconnect AC power. Repower the controller allow unit to complete the update process.

BATTERY

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 setup menu.

SUB MENUS

ENTER

When the controller powers up the very first screen displays the version number for a few seconds. When unit finishes update remove thumb drive then follow the Install Wizard menu.

HISTORY

UP ARROW =

ESC

MAINT

EDIT

+

DOWN ARROW =

-

DEALER

ENTER

- Language +

ESC



English



Fuel Selection

ESC



NG or LP  Select “Yes” and Press “Enter” to continue or Press “ESCAPE” to escape out of updating.

ESC



ESC

ESC

02/12/13 12:31



Possible Message(s) "Corrupted File" "Invalid File" "File Not Found" "Unsupported Device" "Insert USB"

EXERCISE TIME 

14:00 Wednesday

Firmware Update 

Press Enter



Firmware Update

0198170GST-E 02/20/14 Page 3 of 4

During update process the Blue “Manual” light flashes, then the Green “Auto” light flashes. Sequence does this once for firmware (single file) and twice for firmware and hardware (two files)

- Current Date/Time +

Disabled Press OFF



Firmware Update

ENTER ESC

- Insert USB +

System not in the OFF position

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.

"Current:V XXXX "

ENTER ESC

"USB:

V XXXX"

"Are You Sure?"

ENTER ESC

"- Yes or No +"

2013 EVOLUTION/SYNC 2.0 HSB DEALER ACCESS MENU MAP

MAIN DISPLAY

Switched to “OFF” Hours of Protection 0 (H)

To access Dealer Menu enter Password from MAIN DISPLAY: Up, Up, ESC, DN, Up, ESC, Up, ENTER

ESC

“Battery Voltage” 0 - 13.7

Note:Unit needs to be activated to access the Dealer Menu.

ESC

ESC

ESC

ESC

ESC

Startup Delay (sec) 

ESC



*

Run Hours (H) 

0.0

*



Util Volts Low Value 

140 - 171





190 - 216



*



*

1186 - 1780



*

750 - 1280



Press “ESCAPE” to return to previous setting.



No or Yes



ESC ENTER



140 - 156



EDIT

DEALER ESC ENTER

ESC



175 - 198

No or Yes



DEALER:



0.0

*



*

0

Output Volts” 0

“Output Frequency (Hz)” 0.0

0.0 1640 

1120

ESC

ESC

INPUTS: Utility 0

V

0 0 0 0 0 0 0 0

OUTPUTS:Gen.

0 V

0 0 0 0 0 0 0 0

EcoGen Only

To Test Displays Press Enter

ESC

Off Grid Mode

IN AUTO PRESS ENTER FOR QT-TEST

*

ESC ESC

ESC ESC



ENTER

UP ARROW =

+

ENTER

-

ESC

0

ESC

Utility Input Volts 0

FIRMWARE V 1.01 HARDWARE V 1.05

Bootloader V0.2 EEPROM V1.01

COMMAND: Switched Off

Commands: “Running Manual” “Running - Utility Loss” “Running - Remote Start” “Running - 2-wire Start” “Running - Exercise” “Switched Off”

ESC

ESC or ENTER

STOP Quiet Test DOWN ARROW =

Engine Speed (RPM)

TEST

ENTER

Calibrate Current 1, Calibrate Current 2, Calibrate Volts. Special note: Press Enter to modify use the Up and Down arrows to make the change. Pressing Enter or ESC saves the changes. This is different from all the others under Dealer Edit.

(Performs Segment test of the display)

*

DEALER EDIT

1640 

Calibrate Volts 

ENTER

ESC

DISPLAY

PRESS ENTER TO

0198170GST-E 02/20/14 Page 4 of 4

Run Hours (H)

ENTER



Reset Maintenance 

ESC

MAINT

Yes or No

ESC

“Charging” or “Not Charging”

ESC

HISTORY

2 Wire Start Select ESC

SUB MENUS

50 Hz Display

Current

Calibrate Volts 

BATTERY

Current

Calibrate Current2 

or

DATE/TIME

“Charging Status”

Util Recovery Volts

Calibrate Current1 1186 - 1780

SYSTEM

selection. Press “ENTER” to save.

ESC

Util Volts Low Value

Util Recovery Volts



ESC

2 to 1500

Press “ENTER” to modify. Use the *“Up” and “Down” arrows to change

ESC

ESC

Node

Hz

Volts

“Stopped - Auto”

15 KW

60

120/240

“Stopped - Alarm”

Note: Units equipped with Quiet Test only. Unit must be in AUTO and have Utility available in order to view this screen and test the Quiet Test function.