SW inverter and generator cycling in and out [RE-wrenches]

[Steve Willey, Backwoods Solar]

Commonly the battery charger overloads a generator as it slowly ramps up the
charge amps in many steps.  As it does the generator load increases, the rpm
drops and, if loaded too heavily, the inverter dumps the generator input and
the generator speeds up again.  After the set delay the process repeats.
The cure is first trying to increase the generator RPM to just within the
inverter's upper limit unloaded, so that there is more margin before it goes
beyond the lower limit.  Then go to SW menu item number 11, and to "Set Gen
AC2 amps AC" and reduce the AC-2 amp limits from the default 30 on the 4024
down to about 10 amps. After it is charging with stability at this lower
rate you increase it a few amps at a time and wait to see what happens.
When you reach the amp setting that causes the generator rpm to again go so
low as to drop the charger out, back off a little and it is fixed.

Now a big question that Trace could not answer: It seems that the AC in #2
amps so set must often be set to about half of what the generator be rated
for, even generators wired for full power on a single leg.  The engine lugs
down with Trace setting (and Trace meter INPUT AMPS AC) reading about half
of what the generator should produce before overloading the engine.  Also a
clamp on external meter will show more amps actually entering than the
setting or the Trace meter.  Customers have reported this several times, and
I have owned two generators where this discrepancy is observed.  Any one
have like experiences or explanation?
Steve Willey   www.backwoodssolar.com
Backwoods Solar Electric Systems


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