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.

Product Information Bulletin

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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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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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).

Product Information Bulletin

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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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).

Product Information Bulletin

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 doesnt 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

wasnt 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. Its 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

Product Information Bulletin

10

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

Output Volts
0

Output Frequency (Hz)

0.0

0.0
1640

1120

ESC

ESC

INPUTS: Utility 0

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

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.