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Generac•PWRfleet

Analysis by Marcus & Team

Generac PWRfleet High Internal Resistance Error

Troubleshoot high internal resistance errors in Generac PWRfleet energy storage systems. Learn diagnostic steps for network connectivity and system settings.

Frequently Asked Questions

•What is the typical lifespan of a PWRfleet battery module?

The typical lifespan of a PWRfleet battery module is approximately 10 years, but this can vary depending on usage patterns, environmental conditions, and maintenance practices.

•How often should I perform a system-wide reset cycle on my PWRfleet system?

A system-wide reset cycle should be performed as needed to address communication errors or other anomalies. A monthly reset is generally acceptable as a preventative measure.

•What are the recommended environmental conditions for optimal PWRfleet battery performance?

The recommended operating temperature range for PWRfleet batteries is between 15°C and 30°C (59°F and 86°F). Avoid exposing the batteries to extreme temperatures or humidity.

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Marcus leads the technical research department at Storage Faults. Together with a team of systems analysts, he specializes in translating complex solar storage error codes into actionable diagnostic steps for the US market.

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How It Works:

The PWRfleet system relies on a network of sensors and communication protocols (Modbus/CAN bus) to monitor battery module performance, including internal resistance. Data from these sensors is transmitted to the central EMS controller, which then relays this information to the cloud portal for remote monitoring and analysis. High internal resistance is calculated from voltage drop under load and internal temperature measurements. Inaccurate data logging or communication errors between the battery modules, the EMS controller, and the cloud portal can lead to false positives.

Important Warnings:

Unauthorized access to the PWRfleet EMS system could lead to misconfiguration or manipulation of system settings, potentially compromising safety and performance. Always use strong, unique passwords for all system accounts. Restrict access to authorized personnel only. Ensure that all network connections are secured with appropriate firewalls and security protocols. Data privacy is critical: Ensure compliance with data regulations.

Recommended Action:

1

Verify network connectivity of the PWRfleet EMS gateway to the internet. Ensure stable Wi-Fi or ethernet connection, and check cellular backup functionality if enabled.
2

Check the Generac PWRfleet portal for any available firmware updates for both the EMS controller and individual battery modules. Apply updates sequentially, monitoring for errors after each update.
3

Use the PWRfleet app or web interface to review the configuration settings for each battery module. Ensure that the BMS settings are correctly configured for the specific battery chemistry and capacity.
4

Initiate a system-wide reset cycle through the PWRfleet app. This may resolve transient communication errors and clear corrupted data logs.
5

Review the system's data logs for any recurring communication errors or anomalies that may be contributing to the high internal resistance readings.
6

Check API status and cloud synchronization status in the system diagnostic menu via the installer app.
7

If problems persist, contact Generac technical support for advanced troubleshooting and potential remote diagnostics.

Possible Causes:

Firmware incompatibility between the battery modules and the EMS controller.
Network connectivity issues preventing accurate data transmission to the cloud portal.
Corrupted data logs on the EMS controller leading to erroneous calculations.
Incorrect BMS configuration settings affecting internal resistance readings.
Over-the-air (OTA) update failure causing partial data corruption.
API errors preventing proper data transfer between the EMS and cloud.

Symptoms:

The Generac PWRfleet EMS portal displays a "High Internal Resistance" error for one or more battery modules. System performance may be degraded, peak shaving capabilities reduced, and backup power runtime diminished. Potential communication errors between the battery modules and the central EMS controller may exist.

Expert Tip:

Access the service menu in the Generac PWRfleet app (typically by tapping a specific area of the screen multiple times). Check the real-time communication status between the EMS controller and each battery module. A timeout or error code indicates a communication problem. Consider a complete system reset (power cycle the entire system, including battery modules, after safely disconnecting from the grid). Note all system errors before and after the reset.

Prevention:

Schedule regular firmware updates for the EMS controller and battery modules to ensure compatibility and optimal performance
Implement routine capacity testing to monitor battery health and identify any degradation in performance
Monitor thermal conditions within the battery enclosure to prevent overheating, which can accelerate internal resistance increases
Regularly review system data logs for any warning signs of potential issues