[RE-wrenches] Outback VFX input voltage cycling

[Ron Young]

Hello all,
Report from my last visit and some generator forensics. The 240v  
generator plug was wired for only one leg and terminated at another  
plugbox on the wall of the shed. This other plugbox had basically  
fried internally and when disassembled pretty much came apart,  
carbonized wires. So when I measured the output from the genset under  
load, at the generator it appeared ok. When the voltage was measured  
at the FX terminals, with no load, it was ok but as soon as a load  
was applied the voltage began cycling up and down, presumably as the  
resistance in the generator wall plug increased. The attempt of the  
FX to connect AC-In was immediately dropped as the load of the  
charger kicked in, thus the click after 20 secs. as it attempted to  
connect then dropped the connection.

I re-wired the genset plug for both legs then wired it into an  
Outback FW-X240 to balance the output into the FX and everything is  
now working A-OK. Although the system had previously been working for  
several months the eventual deterioration of the wiring in the  
plugbox on the wall led to it's downfall because the FX was only  
getting half the output from a 3800w generator at best. The generator  
was improperly wired, by the homeowner presumably, and could have led  
to a fire. I just wish I had spotted this problem on the first visit  
but working in a dark outdoor shed with a headlight in -25 C temps  
has it's limitations.

Thanks to everyone for your input and may the New Year bring us all  
the sun, wind and water we need to green the planet.

Ron Young
earthRight - Solareagle


On 31-Dec-08, at 10:43 AM, Darryl Thayer wrote:

> HI all and Ron
> In my previous post I said the inverter FET board, I am wrong, it  
> would have to be the AC board or the generator is running out of  
> frequency spec.
>
> Place a load on the generator, so it runs in power note idle, use  
> your meter to measure the generator frequency, set the inverter to  
> not charge, have no load on the output of the inverter, Try as you  
> have done.  The inverter should connect offering very little load.   
> If the same effect, measure the surge current to the inverter using  
> your meter.  I think the surge should be very minimul.
>
> Darryl
>
>
> --- On Tue, 12/30/08, R Young <solareagle at solareagle.com> wrote:
>
>> From: R Young <solareagle at solareagle.com>
>> Subject: Re: [RE-wrenches] Outback VFX input voltage cycling
>> To: "Christopher Freitas" <cfreitas at outbackpower.com>, "RE- 
>> wrenches" <re-wrenches at lists.re-wrenches.org>
>> Date: Tuesday, December 30, 2008, 1:29 AM
>> Hi Chris,
>> My answers appear below:
>>
>> On 29-Dec-08, at 10:41 AM, Christopher Freitas wrote:
>>> When you tested just the inverter without the
>> generator running – you stated that there was a noticeable
>> flicker every 20 seconds –
>>
>> THE GENERATOR WAS RUNNING, IT'S JUST THAT I TURNED OFF
>> ALL THE LOADS TO SEE IF THE PROBLEM WOULD PERSIST AND I
>> FOUND THAT THE RAPID CYCLING OF THE VOLTAGE AT INPUTS QUIT
>> AND THE VOLTAGE STABILIZED AT ~121V BUT ABOUT EVERY 20
>> SECONDS, JUST WHEN YOU WOULD EXPECT THE AC-IN TO GET PICKED
>> UP BY THE INVERTER THERE WOULD BE AN AUDIBLE CLICK, THE
>> VOLTAGE WOULD SUDDENLY DROP TO ABOUT 110V, THEN IMMEDIATELY
>> RECOVER TO ~121V. AT NO TIME DID THE AC-IN GET PICKED UP.
>>>
>>> When the generator was connected to the inverter –
>> was the varying AC input voltage viewed on a digital test
>> meter or on the MATE’s display?
>>
>> I WAS MEASURING THE AC INPUT VOLTAGE WITH A FLUKE METER AT
>> THE INPUT CONNECTORS ON THE FX.
>>>
>>> Is this a 120/240VAC “split phase” generator
>> operating with only one inverter on it?  It is possible that
>> an internal connection in the generators windings has fried
>> due to overloading one output leg of the generator – its
>> similar to a bad solder joint where the voltage is OK until
>> current is pulled and then it opens up.  You might try
>> putting the inverter on the other leg to see if you see the
>> same issue.
>>
>> THIS IS A POSSIBILITY THAT I WILL LOOK INTO. IT IS RUNNING
>> ON ONE LEG OF A 240V GENSET, NOT THE IDEAL SITUATION.
>> I'LL BE PUTTING A PSX240 ON IT TO BALANCE THE OUTPUT BUT
>> WILL FIRST CHECK TO SEE IF IT WILL RUN OK ON THE OTHER LEG
>> BY ITSELF.
>>
>>>
>>> Be sure to check the frequency of the generator when
>> seeing issues like this – its often the problem.
>>>
>>
>> THAT'S ON THE SHORT LIST, THANKS
>>
>> Thanks all who have offered suggestions, I'll check
>> back in with whatever I find out.
>>
>> Ron Young
>> earthright - Solareagle
>>>
>>>
>>>
>>
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