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William and Wrenches,

Oh, yes. Been there. When we specified an inverter for this residence about three
years ago the ONLY 48-volt, battery-backup, grid-tied, UL-listed inverter in the
world (as far as my research could reach) was the AEI MM5000. Xantrex had
temporarily lost the UL listing, Vanner was having problems, and Outback wasn't
ready. 

The first MM failed spectularly about 6 months later--smoke alarms, fire
department, and client alarm phone calls and emails included. This was the most
challenging phone call I've ever received from a client.

The next unit was likely the last one squeezed out the door as the company
folded. To their credit AEI did send the thing--though freight collect.

This second unit failed last fall, two years later, and also in a spectacular
fashion (lot's of smoke, fire department sirens, and phone calls). This was the
second worst phone call I've received from a client, and now the whole house is
being audited by the authorities as a result of the AEI failures.

I called Beacon regarding these failures, and told them that this was the second
"spectacular" failure, and a well-publicized installation (see
www.oceansolar.com, though wait until after I update the web site in a week or
so). Beacon told me that they would consider replacing the MM with their unit at
a heavy discount, and would let me know. I never heard from them. Though they did
not purchase the liabilities of AEI I expected a return call as promised,
especially given the history. This would have been a really good PR thing, too, I
think.

The second fried MM was removed, and replaced with two Outback GVFX3648's and
three MX-60's (we have three PV orientations). I provided these components (and
installation) were at about cost.

Most unfortunately the master Outback unit died in February (and only a few
months after the install). This was most unfortunate, especially as the stakes
were high. It ends up that the Outback unit had a bad (and, I was told improperly
installed) temperature sensor.

The repaired Outback unit is working well after a few days of on-site burn-in.

A summary to this story:

1) I would strongly discourage using a Beacon inverter unless they would like to
drive to my shop and pick up the two fried MM units, profusely apologize for
their lack of response, and donate two of their equivalent inverters, with extend
warranties. Though they did not have legal responsibility for AEI's problems they
did have a responsibility to attend to those who they said they'd respond to (I
would think especially given the PR opportunity). I'll report on any substantial
response from them.

2) Outback, my hopes have been high for your products, and I have been a staunch
suporter. It was crushing that a temperature sensor was not installed correctly,
though you are under the microscope, given the history of this installation.
Please get on with your QA! My client tells me that if there is any other
equipment failure the entire system will be ripped out (see the web-site for
what's here--a lot).

This experience has cost me a tremendous amount, as this site is rather remote,
and requires an 8-hour round-trip drive, in addition to planning. Then there's
the work to do. This has also cost us all, in that the credibility of PV hardware
is at stake.

I'd like to see the manufacturers of this equipment offer a warranty that
includes the time and expense to troubleshoot the problem, plan and drive to the
site, and make good on equipment changes while under warranty--even if at a lower
than normal rate for the contractor. Our financial sustainability is at stake, I
think.

For those of you who might feel this is a bit strong, NO, this does not belong in
another RE group. This is the real story, and a real response.

Gary Higbee
Windstream Solar
Energy Trust of Oregon Inspector


On Wed, 30 Mar 2005 17:24 , William Korthof <wkorthof@earthlink.net> sent:

>
>I have a customer from back in 2002 whose MM5000 inverter just bit
>the black, gooey, smokey, smoldering....dust. Luckily the inverter was
>installed outside, so the toxic black cloud of inverter companies gone
>south only engulfed the yard and not the garage/kitchen/living room.
>
>Luckily, this is our last customer with a MM...and our third MM to go
>bad on us. This one definitely sizzled more the others, with that deep
>putrid black residue totally encrusting the interior power section.
>There are no hints to the cause of failure---three years working, now
>failure. We did not take up Beacon's "upgrade" trade-in offer, but I'm
>not convinced that would have been a good deal... any other dealers
>with MM products still in the field? Is this fiery failure mode common?

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