After-Market Kit Installation and Troubleshooting Guide (Version 2)

The latest Aftermarket Gateway kit (G0097460) and universal harness (A0006648426) 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 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 or space for magnet mounting of gateway. Gateway should be mounted in interior of gen controller enclosure where possible to limit vibration and weather exposure.

3. Connect included cell antennae to AN1 and ANT2 ports on side 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 side 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 terminal blocks (2 green and 1 black).

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.

   1. Connect pre-wired 20 pin black terminal block to connector on right side panel of gateway that has GPS and Wi-Fi antenna posts.
      

9. Connect 8 pin and 2 pin terminal block to left panel side of gateway.

   

10. If included ethernet cable is being used for modbus communication to equipment, connect to the ETH1 port on front of gateway.
    

    

    
    

11. External device will need to be programmed with like IP address for communication to be established.

Wire Termination Setup Detail

The table below outlines each connection for the advanced aftermarket gateway and universal harness, detailing how they interface with the equipment to be monitored.

Troubleshooting

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

Front Panel Indicators and Components

Verifying Proper SIM Installation

1. Power off the gateway.

2. To open the SIM card slot, a paper clip needs to be inserted in small hole located on card holder. Hole can be seen toward edge of extended holder in picture provided.

3. 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 (as part of the same tray) 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.
   

   

Using a LAN-Based Internet Connection

For LAN wired internet connectivity, ports 443, 5671, and 8883 must be open for outbound traffic on the facility firewall, if applicable. The customer-provided Ethernet connection must be configured to assign the Generac Link gateway an IP address via DHCP.

1. Run network cable from customer’s nearest network infrastructure to a laptop.

2. Verify that the network cable has an active internet connection by opening a web browser and attempting to access http://www.google.com .

3. If laptop test is successful, connect Ethernet cable to ETH2 port on the gateway. If test is not successful work with facility IT to resolve.

4. Power off the gateway.

5. Remove SIM card(s) from the gateway.

6. Power on the gateway.

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

Changing Communication Option from Serial to Ethernet

1. Enable the Modbus TCP port on the asset controller.

2. Set the controller IP address in 192.168.3.x (any value, with the exception of 192.168.3.100).

3. Set subnet mask to 255.255.255.0.

4. Run ethernet cable and connect to asset controller Modbus TCP port as well as ETH1 port on Generac Link gateway.

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

Data Values of N/A

A connectivity issue may exist between the gateway and the network.

Steps to resolve

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

   

2. If PWR light is Off, check voltage at + and - terminals.

3. To verify the gateway's cellular connection, check the NET light. A solid light indicates an active connection. If the NET light is blinking continuously, try the following steps to resolve the issue.

   1. Ensure both antennas are securely connected to the ANT1 and ANT2 ports on the gateway and positioned to maximize cellular signal strength. After confirmed, reboot gateway.

   2. Verify Verizon coverage using Verizon’s coverage checker.(https://www.verizon.com/coverage-map/). If needed, check whether alternative carriers (such as AT&T or T-Mobile) provide better reception. We recommend consulting local site contacts for assistance.

4. 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 -99.0 indicates a Modbus communications issue.

To resolve this issue, take the following steps:

1. Verify that the asset communication port settings align with the specifications in the controller-specific installation instructions.

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

3. Power cycle the equipment controller.

One or More Hardwired Digital Input Statuses Are Not Showing Correctly

1. Confirm black wire is landed securely at right panel connector, terminal 4.

2. Ensure the corresponding input wire has DC+ present and is common to the DC+ at the gateway harness red wire.

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.

4. If the above steps do not resolve the issue, the harness may need to be replaced. To do so, place an order using part number A0006648426 by submitting a Support ticket. Once the new harness arrives, follow these steps again.