[RE-wrenches] XW Pro Firmware 2.04 melting devices

Thu Apr 25 11:19:49 PDT 2024

Could be the Gen but...

When you update an offgrid XWP that has been running fine, I would say 
did you follow the commissioning guide and set the grid code? This has 
to be done or you are rolling the dice. All other devices are fine for 
update.

Many older XWP's did not have a grid code. When you update XWP, it will 
cause a mess.

I leave XWP firmware offgrid alone unless there is a compelling reason 
in the release notes.  It is in the FW release. Most all offgrid apps 
run fine with their fw no matter what any one (support at Schneider) 
tells you!

https://solar.se.com/us/en/xw-pro-commissioning-guide/

If this is you Kevin, start from scratch with the guide. You can check 
if there is a grid code set.
  I have to go but I know I owe you an email. Busy  Good Luck!

Dave Angelini Offgrid Solar
"we go where powerlines don't"
    [1]https://offgridsolar1.com/ [2]  [1]
e-mail  offgridsolar at sti.net
text 209 813 0060

On 2024-04-25 10:24 am, Kevin Pegg via RE-wrenches wrote:

> Hi Wrenches,
> 
> Curious if anyone else has seen this issue.
> 
> New XW Pro off-grid system installed Dec 2023. Pretty standard config 
> for us, XW Pro, 5 kW PV, 50 kWh UnigyII battery, 8 kW high quality 
> diesel generator. This system ran fine all winter long - powering 
> customer's big RV they were living in while the house is built, Shop, 
> computer controlled outdoor wood boiler, domestic loads + 3 person 
> construction crew. Gen ran daily on auto start as we don't get much sun 
> Dec - Feb. No issues reported.
> 
> Couple weeks back I did a new system check up. All performing well, 
> happy client. Part of that service I upgraded the XW firmware from 1.09 
> to 2.04, and insight from 1.16 to 1.18. Gave the system a quick check, 
> ran gen. Lots of sun now, batteries full so didn't do a long generator 
> test. Yes I set the region codes for off-grid.
> 
> A week later, while I was out of town and it was not so sunny so gen 
> running, client and their electrician called me in a panic. Two smoke 
> detectors had literally melted, as well as several dimmable LED 
> fixtures all failed. Electrician replaced the burned up devices, only 
> to have the same thing repeat a few days later. Talking with them it 
> was only when the generator was running there were issues. Told them to 
> lock out gen and I will get there when I can.
> 
> Once back I attended site, fired up gen, and could hear the inverter 
> sounding terrible during gen charging. Lights flickering bad, and I 
> personally verified the smoke detectors beeping and getting warm and 
> the house smelled like burned plastic. I hooked up my power quality 
> analyser and could see the THD gradually building to over 36%. Gen 
> voltage was at 125/250V a bit high, so adjusted that, but no change. By 
> reducing the charge rate on the XW Pro to 50% was able to get the THD 
> down around 12% and less light flicker. But it's still too high. Image 
> attached shows THD with gen on original programing, then at reduced 
> charge rate.
> 
> Have now gone from a happy client to a pissed off client threatening 
> legal action for endangering their lives & a bill from the electrician. 
> Ugh. Having a hard time explaining this to the client why a system 
> previously working fine went sideways so badly. Old guy blames the 
> "darned computer stuff" and he's not wrong with that opinion.
> 
> At another site, similar config but larger system with dual XW's that I 
> upgraded to 2.04 firmware remotely few days ago and now the two 
> inverters are literally fighting each other under generator charge - 
> one load building to +6 kW and one (minus)6 kW.
> 
> Sure makes me reluctant to upgrade firmware on systems that are working 
> fine.
> 
> Any suggestions?
> 
> Kevin
> 
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Links:
------
[1] http://members.sti.net/offgridsolar/
[2] https://offgridsolar1.com/
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