[RE-wrenches] FLA battery problelm

Sat Dec 13 11:55:22 PST 2025

Yes, the "not above 52vdc" part sure makes it sound like some unfound
corrosion or poor connection in between 2-3 cells. Hopefully they can be
saved and you'll be a hero!

Nick

On Sat, Dec 13, 2025 at 11:13 AM pieter offgridenterprises.org <
pieter at offgridenterprises.org> wrote:

> I couldn't agree more with Ray. Those batteries are tough. Assuming there
> is adequate charging capacity the batteries have a very good chance of
> recovering. That being said the renter has to be trained! Simply spending
> more money to replace the Hup batteries wit a set of new LIPO batteries
> will most likely trade one problem for another. As others have already
> pointed out: If energy in is less than energy out the batteries will not be
> able to make up the difference. Even LIPO batteries.
> Pieter Huebner
> Project Manager
> Off Grid Enerprises
> ------------------------------
> *From:* RE-wrenches <re-wrenches-bounces at lists.re-wrenches.org> on behalf
> of Nick Lucchese via RE-wrenches <re-wrenches at lists.re-wrenches.org>
> *Sent:* Friday, December 12, 2025 11:41 PM
> *To:* RE-wrenches <re-wrenches at lists.re-wrenches.org>
> *Cc:* Nick Lucchese <lucchesesolar at gmail.com>
> *Subject:* Re: [RE-wrenches] FLA battery problelm
>
> Are you able to get near the 75 amp charge rate with the SW's charger and
> that 7.5 KW generator with a step down transformer maybe? Neither charging
> combos can push the voltage above 52? All the bus bars and hardware have
> been cleaned and reassembled recently or not since 2022? Have you made any
> other observations looking over that 128 day logging menu?
>
> Battery banks prematurely heading to the smelter is the unfortunate
> reality of our systems of the past. Chasing that mostly unrealistic goal
> that the bank will do some dramatic turn around to redeem everyone's
> efforts may likely result in more wasted time and money. Replacing with a
> lithium pack that offer's it's own onboard SOC capacity meter is almost a
> necessity with renters. Removing the unknown cloud around
> understanding what the battery needs results in a much more enjoyable
> homestead experience and engages the renter to be accountable for
> recharging. Offerings from both Midnite and Rubix can be had for less than
> $.28 a watt hour retail these days. Impressive times for folks storing
> sunshine. The sooner it goes in the sooner the fuel savings and lack of
> service calls can start paying it off.
>
> I always default to Midnite first for quite a few reasons and especially
> for `UL9540 but Rubix might be a better solution in this case since that
> volatile memory Steve mentions might become a concern if a trained
> individual isn't frequently checking up on the system to make sure all the
> settings are still in tune with the battery. Besides for LBCO, SW default
> settings are quite ideal for all of the Rubix series. You also gain the
> bonus of a digital net power meter on the battery to validate the SW's
> meter screens along with the Outback logging menu.
>
> Nick
>
>
>
> On Fri, Dec 12, 2025 at 10:21 AM David Coale via RE-wrenches <
> re-wrenches at lists.re-wrenches.org> wrote:
>
> Hi Wrenchers,
>
> I have a client with an old off-grid Trace system and he is having trouble
> with the batteries.  He has HUP Solar One FLA batteries that are about 4
> years old, so they should be in good shape.  The last set lasted almost 20
> years with a fair amount of abuse.
>
> Here is he history and what I think is going on. 7/21 they got new
> batteries after about 19 years of use.
>
> 7/22 I get a call saying the batteries are not charging up all the way.
> When I check out the system, the batteries needed cleaning, and I found
> three low cells, and the charger settings were back to default, not set
> high enough to charge the batteries all the way (it’s always multiple
> problems).  The client (now a new renter, new to the system) said he was
> filing the batteries once a month and experienced some overflowing when the
> batteries were charged up.
>
> I cleaned things up, reset the charging parameters and set up an
> equalizing charge to even out the cells. Hopefully this will fix things.
>
> 11/25. The client calls and said the batteries don’t charge up all the way
> and he is running the generator a lot and worried about getting though the
> wintertime.
> When I check things out, there are three bad cells and there is soda on
> the batteries. It is hard to get a good voltage readings because of the
> soda. Most of the cells are reading 2.1 volts under about a 40 amp load.
>
> Yesterday I check things out, and all the cells are reading between 1.93
> to 1.98 under a 40 amp load in the morning, and I don’t find any bad
> cells.  The charging voltage is never going over about 52 volts so the
> system is never getting fully charged up.  The charge setting look OK, so
> not sure what is going on. This is acting like an old battery pack but
> these batteries are relatively new.
>
> My guess at this point is that maybe the batteries lost acid with the
> overflowing event and lost capacity.  Maybe adding acid back in would bring
> them back up to working order.  The SG measured at 1.150 or less.
>
> At this point the client (renter) has had enough of these battery problems
> and is wondering every morning if the batteries will last long enough to
> until the sun comes up.  The renter is pushing for a replacement LFP
> battery, but there should be lots of life left in this battery pack.
>
> Let me know what you all think.
>
> Thanks,
>
> David
>
>
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