[RE-wrenches] FLA battery problelm

Sat Dec 13 13:54:08 PST 2025

Oddly, we have two questions where the Outback is only getting to 52
volts. I mentioned in the other thread that these could be the DC Generator
Voltage settings. I'd say it here as well.

Please check the DC Gen settings in the AGS. For a 48V system, set it to
76V if you are using an AC Genny.

*Steve Higgins* *⋅* *Technical Services Manager*
*t* +1.902.597.4020   *m* +1.206.790.5840
*f* +1.902.597.8447   *e* steve at surrette.com
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On Sat, Dec 13, 2025 at 12:08 PM Ray Walters via RE-wrenches <
re-wrenches at lists.re-wrenches.org> wrote:

> I spent decades talking folks through recovering HUPs that had been
> chronically under charged.   The fact that the batteries are just hovering
> around 52 v and not breaking out above that is another sign that there is
> capacity left.  Its when they charge right up to 58 v and go into float
> before 10 AM that you have no capacity left. That hovering at partial SOC
> is because there is not a high enough charge rate.
>
> They need to start the generator in the morning, so that both the
> generator and the solar can work together to have a high enough charge rate.
>
> Equalize, Equalize, Equalize, they will come back to full charge, but yes
> they will have lost some capacity from when they were new. These batteries
> could easily last another 5 years if recovered.
>
> We're not talking 2 to 4 hours of generator charging either, we're talking
> like 12 hours a day possibly, for 3 to 4 days.  You just keep going until
> the SG comes up.  Period.  Then bring them to full charge every week to 10
> days, and don't let them sit chronically under charged again.
>
>
> More solar or a drastic weight loss program is the only way to make this
> system work long term.
>
>
> Ray Walters
> Remote Solar
>
>
> On 12/13/2025 12:13 PM, pieter offgridenterprises.org via RE-wrenches
> 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>
> <re-wrenches-bounces at lists.re-wrenches.org> on behalf of Nick Lucchese
> via RE-wrenches <re-wrenches at lists.re-wrenches.org>
> <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>
> <re-wrenches at lists.re-wrenches.org>
> *Cc:* Nick Lucchese <lucchesesolar at gmail.com> <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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