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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)
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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
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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.