restosud
was trying to use an evolution panel from a 2013 generac 20kw air cooled on a 2016 22kw air cooled and got this message.
needed to try this known good 2013 controller as i'm having stepper motor issues and wanted to confirm it was not the controller first.
How do you override this message?
i did not try the 20kw resistor into the 22kw harness as it was late and also didn't want the controller thinking it was on a 20kw.
there was a thread about this message back in 2013 but not very conclusive.
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MacL
There is no way to override that message.  It may be that you just plugged the connectors in the wrong sequence.

You have to insert the plug with the resistor on it before you insert the other plug.  I believe the smaller of the two large connectors is the one with the resistor and needs to be plugged in first.

The other two connectors are the stepper and the dpe/brush wires, and they can be plugged in at any time.
State your problem, not your diagnosis.
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Peddler
I think you will find one is an EVO 1.0 controller and the other is an EVO 2.0 controller and they are not compatible.
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restosud
Peddler wrote:
I think you will find one is an EVO 1.0 controller and the other is an EVO 2.0 controller and they are not compatible.


i thought the software version was what mattered and the 1.0 and 2.0 were just updates? didn't know there was hardware differences.
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ohmslaw
If you plug an evo 2 into an evo one gen that is connected to the grid sparks will fly and you will need a new controller.
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restosud
don't doubt any of this but both controller are 0j8371c versions.double checked on the generac's site and both the 2013 and 2016 use the same part number controller.
assuming the ones i have are both evo 1's
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restosud
according to ziller,
  https://www.zillerelectric.com/products/generac-0j8371c-2013-air-cooled-evolution-sync-2-0-control-panel?_pos=177&_sid=06f66fea7&_ss=r
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restosud
MacL wrote:
There is no way to override that message.  It may be that you just plugged the connectors in the wrong sequence.

You have to insert the plug with the resistor on it before you insert the other plug.  I believe the smaller of the two large connectors is the one with the resistor and needs to be plugged in first.

The other two connectors are the stepper and the dpe/brush wires, and they can be plugged in at any time.


thanks Macl, i ordered a new stepper/mixer assembly and will follow your directions when it arrives.
btw,the generator is not currently hooked up to the grid.just a trial run to see if it was outputting. 
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Geoff Z
We check against the serial number in GenService. We’ve had some bad experiences. When a controller or any part ships out we do our best to be positive it is the right one. 
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restosud
Here is the complete story on this G0065512 22kw unit.
Bought it from someone near hammond LA on craigslist.It was installed in June 2016 and was subsequently flooded in august of that year.Went to check it out and it started fine but would not really produce electricity. The mlcb had been wired incorrectly by whomever tried to salvage it post flood.
Controller looked to be good but didn't want to spend too much time diagnosing the generator there.one phase seemed to be working but the other was iffy.Informed owner that it looked like the rotor/stator combo might be defective and he agreed as it would not run any load.
He agreed to let it go for $200,i figured what the heck,controller and some engine parts were easily worth that.
Got it home and ran more tests,megged the rotor and stator with flying results.the slip ring was pitted and out of round,1 brush was shorter than the other,the mlcb and 15A breaker were defective. Separated the generator from engine,pressure washed everything,trued the slip rings,put new brushes,rear bearing,new breakers and ran it. Got voltage out of it but stepper was defective. removed the intake manifold to clean it as it had a coating of fine silt in the runners,installed new stepper and now have  a functioning unit.242 volts and 60 hz on the nose.No particular noises from the engine and doesn't seem to burn oil..
Tried a back up controller (firmware 1.06/hardware 1.05) but still get the "model ident problem,fix harness resistor" message with the original 22kw OK0258BB 365 ohm resistor. If i use the resistor from a 20kw 0062440 ( part OK025J ,1.810K ohm)then message does not appear.

the later controller can be used with either resistor with no error message.
I was aware that there are different firmware versions,but the hardware i did not know seeing that both controller have the same part number.

Lastly,is it possible to update the controller if unit is not connected to the grid or transfer switch and just running freestanding on the battery?
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BrianMartin
Yes it is possible to update the controller on battery power without a transfer switch.
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ohmslaw
The resistor corroded from the flood. Cut it open and reconnect the end that broke. you only need it for initial power up or any time the controller is powered down.
You could also just use the 20 KW resistor it will just overload at a lower amperage. We see this issue a lot when customers let the irrigation system flood the unit.
Tim
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restosud
Updated firmware to version 1.17 and error message no longer appears no matter which resistor is plugged in..
Tried the long version of updating with dealer code and multiple step process described in service manual and got "no file found" message.
Tried the fast way by pulling the fuse and plugging in the usb key and then putting fuse back in and it worked like a charm!

All good to go finally, and thanks for all the help.
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restosud
ohmslaw wrote:
The resistor corroded from the flood. Cut it open and reconnect the end that broke. you only need it for initial power up or any time the controller is powered down.
You could also just use the 20 KW resistor it will just overload at a lower amperage. We see this issue a lot when customers let the irrigation system flood the unit.
Tim


How does the controller know that overload is reached on a 22kw?

Both the 2013 MY 20kw that i have have current transformers that would tell controller how many amps are being pumped out, but the 2016 MY 22 kw doesn't have them.
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grsthegreat
ive never sen one without the CT.
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restosud
even according to service manual schematics,not all generators have the ct's.
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