The Generac 2-Wire Gen Start Kit is a critical component for enabling remote and automated control of backup power systems. This kit is part of the broader Advanced Gateway system, which supports industrial IoT connectivity through the Generac Link Manager platform. This guide provides a detailed, step-by-step installation process based on the technical specifications and instructions provided in official installation documentation. The guide is structured to cover hardware preparation, wiring procedures, antenna and power setup, troubleshooting, and network configuration.
Overview of the 2-Wire Gen Start Kit
The 2-Wire Gen Start Kit is part of the after-market Advanced Gateway package, designed for integration with Generac backup power systems. This kit is used to establish a communication link between the gateway and the generator controller, enabling remote monitoring and control. The kit includes a relay mechanism that supports both positive and negative signal inputs for the "On" condition of the generator.
The gateway communicates via Modbus TCP and supports cellular, Wi-Fi, and GPS connectivity. It is essential for technicians to verify that the correct components are included and to follow the installation steps carefully to ensure a stable and secure connection.
Hardware Components and Tools
For a successful installation of the 2-Wire Gen Start Kit, the following hardware and tools are required:
- Communication gateway (Part numbers: BP-ADVGW-V1 or G0097460)
- Ethernet network cable (CAT5)
- 120VAC power supply (not typically required)
- RS232 comm port breakout board and cover
- Cellular antennas (2 included)
- Verizon SIM card (pre-activated)
- GPS antenna
- Wi-Fi antenna (optional)
- Easy connect harness
- Din rail
- Four-position terminal block for Generac Power Zone Pro Sync Display RS485 port
- Four-position terminal block for Generac Power Zone Gateway RS485 terminal block
Technicians should also bring the following software and documentation:
- Access to Genlink software
- Modbus master simulator (e.g., Modscan 32 or Modscan64)
- Windows laptop with an Ethernet port
- Equipment controller documentation
- PLC programming software
- Wireshark software (for network diagnostics)
- Multimeter with AC/DC voltage, AC/DC current, and resistance measurement capability
It is also recommended to have spare parts on hand, including:
- Spare 12/24 VDC relays
- USB to RS485 and RS232 converters
- Spare gateway and wire harness (as replacements if necessary)
Pre-Installation Checklist
Before beginning the installation, a technician must complete a series of site deployment checks to ensure the environment is suitable for the gateway and associated equipment. These checks include:
- Voltage verification
- Condition of circuit fuses
- Availability of a suitable mounting location (preferably inside the generator controller enclosure to minimize vibration and weather exposure)
- Inspection of the wiring harness to confirm that the gateway and customer ends are correctly identified
If any components arrive damaged, the technician should contact Generac Support to open a ticket and request replacements. It is also recommended to schedule a consultation with a Generac Solutions Engineer prior to installation, especially if the site involves multiple generators, ATSs, or fuel sensors connected through a single gateway.
Installation Steps for the 2-Wire Gen Start Kit
Mounting the Gateway
- Identify the mounting location. The gateway should ideally be mounted on an existing DIN rail inside the generator controller enclosure. If a DIN rail is not available, a suitable mounting location must be identified that limits vibration and weather exposure.
- Mount the gateway. Secure the gateway using the included DIN rail or appropriate mounting hardware. Ensure the unit is stable and not subject to physical movement or environmental damage.
Antenna Installation
- Connect the cellular antennas to the AUX and ANT ports on the top of the gateway. These antennas should be mounted as close to the outside of the generator enclosure as possible.
- Separate the antenna ends by approximately 12–18 inches to optimize signal strength.
- Install a drip loop on each antenna to prevent water from entering the unit.
- Mount the GPS antenna near the outside of the enclosure and also install a drip loop.
Power and Ground Connections
- Power the gateway via the terminal block connections. Ensure that the power connections are made directly to the battery posts to avoid intermittent power loss during generator crank.
- Connect the power terminal block to the gateway using the wire color coding specified in the documentation:
- TB1 V+ – Red – DC+
- TB1 V- – Black – DC-
- TB1 GND – Blue/White – GND
Relay and Input Connections
- Harness Relay #1 is used for 2-Wire Gen Start. Connect the following:
- COM – Blue
- N/O – White/Blue
- N/C – Blue/White
- Harness Relay #2 is a spare output. Connect as follows:
- COM – Brown
- N/O – Green/Yellow
- N/C – White/Orange
Input Signal Configuration
The gateway can support either positive or negative inputs for the "On" condition. This is determined by the termination of the orange wire: - If the orange wire is terminated to DC-, the gateway will sense an "On" condition when input wires (Purple/Green/White/Yellow) have a DC+ signal applied. - If the orange wire is terminated to DC+, the gateway will sense an "On" condition when input wires have a DC- signal applied.
Technicians must verify the signal polarity according to the generator controller's specifications.
Network and Communication Setup
Modbus TCP Configuration
- Enable the Modbus TCP port on the generator controller.
- Set the controller IP address to 192.168.2.x (any value except 192.168.2.1).
- Set the subnet mask to 255.255.255.0.
- Run an Ethernet cable from the generator controller’s Modbus TCP port to the GE0/2 port on the Generac Link gateway.
- Contact Generac Support to reconfigure the site for Modbus TCP communications.
If the controller’s IP address cannot be changed due to site restrictions, a Solutions Engineer must be contacted for assistance. If the technician lacks the password to change the communication setup, they should reach out to the IDC master tech or generator support team.
SIM Card Installation
- Ensure the gateway is powered off before handling the SIM card.
- Verify that the SIM card is inserted in the primary slot with the chip wiring facing up. A secondary slot is available for a Hologram SIM card if required.
- Gently push the SIM into place until a click is heard. This ensures the card is securely seated.
- Reinstall the SIM card holder and power the gateway on.
LAN-Based Internet Setup (Optional)
If a wired internet connection is used instead of cellular:
- Ensure that ports 443, 5671, and 8883 are opened for outbound traffic.
- Connect a network cable from the customer’s network infrastructure to the GE0/1 port on the gateway.
- Remove the SIM card(s) from the gateway.
- Power the gateway on and wait 10–15 minutes for live data to appear in the Generac Link Manager.
If the gateway fails to communicate, the technician should contact Generac Support for further assistance.
Troubleshooting
Modem LED Behavior
- If the modem LED blinks for more than 15 minutes, verify that the antennas are properly connected and mounted correctly. Refer to the installation steps for antenna setup details.
Power Light Indicators
- PWR light solid red – The gateway is powered and operational.
- PWR light off – Check the voltage wiring for any faults or loose connections.
- PWR light blinking – The gateway may require replacement. Contact Generac Support to initiate a warranty claim.
MODEM Light
- The MODEM light must be on for successful communication. If it is not, verify that the SIM card is correctly inserted, the antennas are properly connected, and the network ports are open if using a LAN connection.
Network Communication Issues
- If data values show N/A in the Generac Link Manager, there may be a gateway-to-network connectivity issue. Steps to resolve include:
- Confirm the PWR light is solid red.
- If the PWR light is off, check the voltage wiring.
- If the PWR light is blinking, consider replacing the gateway.
- Ensure the MODEM light is on.
- If using a LAN connection, confirm that ports 443, 5671, and 8883 are open.
Best Practices and Additional Considerations
- Schedule a consultation with a Generac Solutions Engineer before attempting to connect multiple forms of equipment through a single gateway, especially in complex setups involving multiple generators, ATSs, or fuel sensors.
- Use the provided software tools such as Modscan, Wireshark, and Genlink for diagnostics and configuration.
- Maintain spare parts on-site, including spare gateways, wire harnesses, and relays, to minimize downtime in case of component failure.
- Verify all connections before finalizing the installation. Double-check wire colors, terminal positions, and signal polarity to prevent misconfigurations.
- Document the installation process, including IP addresses, relay configurations, and signal polarity, for future reference and troubleshooting.
Conclusion
The Generac 2-Wire Gen Start Kit is an essential component in the Advanced Gateway system, enabling remote monitoring and control of backup power equipment. Proper installation requires careful attention to hardware setup, wiring configurations, and network communication settings. Technicians should follow the outlined steps, consult the provided documentation, and reach out to Generac Support for assistance when necessary. By adhering to best practices and verifying all connections, technicians can ensure a stable and secure integration of the gateway with the generator system.