SW4024 charging problems [RE-wrenches]

[David Palumbo, Independent Power & Light]

Jeff,

You need to know what the error message is. I recently had a problem very
similar to this with a dual SW4048 (Rev 4.2 firmware) / 8.5K Kohler genset
system. Ran fine in manual start/stop battery charging mode and with no
inverting problems. In auto gen start mode it started flawlessly and charged
the batteries completely. At the end of the programmed absorption time when
the controlling inverter shuts down the Kohler (the gen did shut down when
it was supposed to) the controlling inverter would go off on a "Input Relay
Error" (not in Trace manual but in the system software). The 3,600 rpm
Koehler's do not shut down as fast as the 1800 rpm units. Rev 4.2 would see
the gen still on (if it waited another spilt second to check for gen
run/shutdown everything would have been fine) and shut the inverter(s) off
due to the "In-put Relay Error").

Solution replace chipsets to Rev 4.1 now everything works very well and this
particular system is now being operated on Auto start/stop all the time.

Dave Palumbo
IP&L

-----Original Message-----
From: Jeff Yago [mailto:jryago at earthlink.net]
Sent: Saturday, January 04, 2003 1:20 AM
To: RE-wrenches at topica.com
Subject: RE: SW4024 charging problems [RE-wrenches]


I have a total off grid client with a single SW4024 inverter, a battery bank
of eight L-16 batteries,160 watts of solar (lots of woods and small south
roof area) which is used just to offset standby losses, and a 8.5 kW propane
generator wired for full output at 120 volts.  System has worked great about
one year as this off grid cabin has minimum loads and only used on weekends.

Now owner is reporting problems.  Generator will charge batteries if
manually turned on, but if he leaves generator control in "auto" mode, when
he returns after a few days the batteries are below 23 volts and error light
on.

No, I have not visited the site yet and the owner could not advise what type
of error light(s).  I am convinced the owner has added some kind of fan type
space heater or other heating load that keeps drawing the battery down this
fast during these colder months, since his initial loads were just a few
compact fluorescent lights, one small micro-wave, a radio, and one Sun Frost
refrigerator, and almost everything stays off until the weekends.  He does
not even have a TV, VCR, or well pump!  Cooking and DHW by non electric
propane equipment.

Assuming some new loads we did not design for are drawing down the batteries
while he is away, this still does not explain why the inverter cannot
maintain battery charge with the generator in "auto" start mode, but works
great in manual start mode with no error messages during or after charging
for 3 or 4 hours.  We are always careful about programming the inverter AC2
input (generator)amps capacity setpoint and the maximum bulk charge amps to
stay well below generator peak capacity, and have not had any problems with
this system in the past overloading the generator.  Owner also swears
inverter has not been shut down (back to factory defaults) since our initial
setup, and nobody had access to control panel to change our setpoints.

Any thoughts on "auto" control verses "manual" generator start control for
battery charging with SW4024, as it relates to causing errors?

Jeff Yago

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