Advanced Gateway After-Market Kit Installation

The Advanced Gateway enables remote control and monitoring of backup power equipment leveraging Generac Link Manager, our cloud solution for industrial IoT connectivity. This topic offers wiring and hardware details as well as some troubleshooting steps for a complete setup that enables continuous communications and remote access.

Commissioning the Advanced Gateway

This topic details the hardware components and installation steps needed to commission an IoT-enabled generator and associated equipment.

Tools Needed

Technicians should bring the following hardware and software to the installation.

Kit Components

For first-time installs, verify that the following hardware is included with the kit.

Other checklist items for Site Deployment include verifying voltage and the condition of circuit fuses. Please follow the steps in this table.

Installation Steps

The remaining steps needed for a complete installation are provided in this section, which details kit components.

1. Identify components included in the kit as provided in the previous section.

2. Identify existing din rail for mounting of gateway or find suitable location to mount included piece. Gateway should be mounted in interior of gen controller enclosure where possible to limit vibration and weather exposure.

3. Connect included cell antennae to AUX and ANT ports on top of the gateway. Mount as close to outside of generator enclosure as possible. Antennae ends should be separated approximately 12”-18”. Installation of a drip loop is required to keep water from entering unit.

4. Connect included GPS antenna to GPS port on top of gateway. Mount as close to outside of generator enclosure as possible. Installation of a drip loop is required to keep water from entering unit.

5. Inspect wiring harness and identify customer and gateway ends. Gateway end will have 3 pre-wired green terminal blocks.

6. Route customer end to be near generator termination points. See generator controller specific reference pages for recommended terminations.

7. Make final connections on customer end per documentation.

8. Connect 7 pin terminal block (TB1) with Red, Black, Orange/White, White/Orange, and Blue/White wires to terminal block receptacle on top of communication gateway.

9. Confirm data cable connections are correct on gateway side for either RS485 (A/B) or RS232 (TXD/RXD) applications. 

10. Connect 8 pin terminal block (TB2) with Yellow, White, Green, Purple, and Orange wires to front side, top terminal block receptacle. 

11. Connect 8 pin terminal block (TB3) with Brown, Black, and Blue wires to front side, bottom terminal block receptacle.

12. If included ethernet cable is being used for modbus communication to equipment, connect to the bottom port on front of gateway labeled “GE0/2”. 
    Gateway default settings:
    IP Address: 192.168.2.1
    Subnet Mask: 255.255.255.0 

13. External device will need to be programmed with like IP address for communication to be established. Suggested IP settings:
    IP Address: 192.168.2.2  
    Subnet Mask: 255.255.255.0
    Default Gateway: 192.168.2.1

Wire Termination Setup Detail

Be sure the wire connections correspond to the guidance provided in this section.

1. Power gateway.

2. Connect power terminal block to the gateways. These are listed in the table in this section.

^{¶The Gateway can support either positive or negative inputs for On condition. If the orange wire is terminated to DC- then gateway will sense an On condition when input wires (Purple/Green/White/Yellow) have DC+ signal applied. If the orange wire is terminated to DC+, then gateway will sense an On condition when input wires have DC- signal applied.}

Troubleshooting

Check this section to resolve any issues experienced while setting up the Advanced Gateway.

Modem LED

If the LED modem continues to blink for more than 15 minutes, ensure that the antenna is properly connected. Please refer to Initial Steps section in this topic for details.

Verifying SIM Position

1. Gateway power must be off.

2. Verify that the SIM card on arrival is inserted in the primary slot, as depicted in the photo, with chip wiring facing up. A backup slot is available for a Hologram SIM card. If specifically requested to do so by Support, insert the SIM into the second position with chip wiring facing down.

3. Lightly push SIM into position until a click is heard.

4. Reinstall SIM card holder.

Using a LAN-Based Internet Connection

If a LAN, wired internet connection is being utilized for connectivity, ports 443, 5671, and 8883 must be opened for outbound traffic.

1. Run network cable from customer’s nearest network infrastructure to a laptop. Make sure a website is browsable. Proceed to next steps if the web is browsable.

2. Power off the gateway.

3. Connect network cable that was connected to laptop to the GE0/1 port on the gateway (part number BP-ADVGW-V1).

4. Power on the gateway.

5. Wait 10–15 minutes then check the Generac Link Manager for live data streaming. If it is not communicating, please reach out to Support.

Gateway Indicator Lights (After Market Definitions)

Changing Communication Option from Serial to Ethernet

1. Enable the Modbus TCP port on the controller.

2. Set the controller IP address in 192.168.2.x (any value, with the exception of 192.168.2.1).

3. Set subnet mask to 255.255.255.0.

4. Run ethernet cable and connect to generator controller Modbus TCP port as well as GE0/2 port on Generac Link gateway.

5. Contact Support to reconfigure site for Modbus TCP communications.

Data Values of N/A

There may be a gateway-to-network connectivity issue. 

Steps to resolve

1. Confirm that the device is on by checking PWR light solid red as provided here.

   

2. If PWR light is off, check voltage wiring.

3. If PWR light is blinking, the gateway may need to be replaced. Refer to this information on submitting a warranty claim. To open a claim, please contact Support to open a ticket. You will be guided on how to proceed.

4. Confirm MODEM light is On.

5. If the light continues to blink with no signal strength light on, make sure the antenna is connected to ANT and AUX ports of the gateway and the antennae are mounted to a place of maximum cellular coverage, utilizing the antenna extension wires if needed.

6. If the device keeps continues blinking with SIM1 and SIM2 lights alternately on and off but have full two or more bars of signal strength lights on, there may be an issue with the network connection.

7. Check Verizon coverage at the site using Verizon’s coverage checker (https://www.verizon.com/coverage-map/). If necessary, determine if alternative carriers (for example, AT&T or T-Mobile) offer improved reception. We recommend reaching out to local site contacts.

8. If the above are verified OK and the application still indicates N/A in the data stream, please contact Support.

Values of -99 Populate Data Stream

A value of -99 or -99.0 indicates a Modbus serial communications issue.

To resolve this issue, take the following steps:

1. Check and compare the settings for the following with the controller-specific installation instructions.

For the RS232

• Baud rate

• Parity

• Modbus address

For the Modbus RS485

• Baud rate

• Parity

• Modbus address

For Modbus TCP

• IP Address: 192.168.2.2

• Subnet Mask: 255.255.255.0

• Default Gateway: 192.168.2.1

2. Confirm proper wiring connections between the gateway and controller.

3. Power cycle the equipment controller.

One or More Digital Inputs (DIs) on Gateway Not Functioning

Check if contacts wired to the digital inputs on gateway are dry or wet contacts.

Dry Contacts

For dry contacts, please connect wires as provided in this image and follow the instructions below.

1. Connect DICOM to DGND on TB2 of gateway.

2. Connect DIx (x = 0, 1, 2, or 3) to NO (normal open) terminal of the dry contact on equipment controller.

3. Connect voltage PCOM to COM terminal of the dry contact.

4. Make sure all DIs on GLM gateway are connected to dry contacts only—a mix of dry and wet contacts will not function.

Wet Contacts

For wet contacts, please connect wires as provided in this image and follow the instructions below.

1. Ensure that voltage on the wet contacts does not exceed 24 volts (DC).

2. Connect DICOM to COM of the wet contact and DIx (x = 0, 1, 2, or 3)  of the gateway to NO of the wet contact.

3. If the above is verified and data is still not streaming, we recommend a gateway replacement.

One or Both Relays on Wire Harness Not Functioning

Command to trigger on/off from platform is failing

1. Make sure there are no –99 values shown on the platform for the equipment under consideration.

2. Listen for click sound when a particular output is triggered on/off from platform.

3. Connect a multi-meter in continuity measurement mode between Blue and White/Blue wires for checking relay#1 or Brown and Green/ Yellow wires for checking relay#2.

If the above steps do not resolve the issue, the harness may need to be replaced, which will require an order using the following part number: BP-ADVGWH-V1. To submit an order, please open a Support ticket. Once the harness arrives, repeat these steps.

What to do if labels on TBs of wire harness are missing

Check number of wires connected on each TB

TB1 will have following coloured wires:

1. RED

2. Black

3. Orange/ White

4. White/ Orange

5. Blue/ White

 TB2 will have following coloured wires

1. Orange

2. Purple

3. Green

4. White

5. Yellow

TB3 will have only 3 wires

1. Blue

2. Black

3. Brown

To verify the gateway side data cable connections on TB1 (OR/WH, WH/OR, BLU/WH), please refer to the table at the top of this help topic.