Dave, 

We haven't seen this particular problem with the FM80, but we've had others.
Specifically, we've seen the "locking up" Howie reported. The customer is now on
their third unit (firmware version 001.009.017). This one puts out 90 amps
occasionally. I don't think it's supposed to do that. As I'm sure you you know,
Outback has a "zero tolerance" rule for unit replacement. If their unit fails
prematurely, through no fault of the client or dealer, they will send you a
remanufactured unit. The dealer is NEVER compensated for their labor to install
it. Outback just offered to send my client Unit #4. The client suggested they
call me to see how I feel about that. I haven't heard from them and am not
holding my breath.

As Bob-O has stated previously, the manufacturers' apparently do not understand
that the dealer is their ultimate client. If they don't support us, we, quite
simply, can't afford to support them. I have a prospective off-grid client for a
large system, to whom I've had to say, "I don't know of a charge controller I
can recommend." Instead, I proposed an AC coupled Sunny Island design, using SMA
Sunny Boys as PV "controllers".

To address your situation; even though your FM80 is "new", it may have an
obsolete firmware version. When introduced it used version 001.009.000. 
No way to tell if a different version will be a fix, or, instead, introduce a
new problem.

If you haven't done it yet, you might want to check out the Outback Users Forum
for the FM80 at:

http://www.outbackpower.com/forum/viewforum.php?f=29

Dick
Solarwind Electic

--- You wrote:
We swapped in a new FM-80 controller on April 2nd and it worked perfectly
until today. It was a sunny day and the FM-80 was in absorption mode by noon
time. The homeowner noticed at 2:30pm that the FM was not in float as it
should have been. It was a typical sunny day with no big loads on. The
homeowner reported that the FM-80 was repeatedly going through a 6 minute
cycle. Snooze for 5 minutes, wakeup 5 seconds, tracking 10 sec, bulk 30 sec,
absorb charge 20 sec, and back to snooze where it began another identical
cycle. The batteries were 100% charged by 2:000pm, the battery voltage was
at 53.5VDC (two OB VFX3648's ON powering lights and drawing 5 amps DC) when
the FM-80 was not in bulk, or absorb charge. When in bulk charge the PV amps
(35A mid afternoon, warm day) were connected to the battery bank the battery
voltage climbed back up to 58 volts quickly. The "tech" we called at Out
Back was not very helpful, "never heard of this situation" and tried to
blame it on poor battery connections,  he could not understand why the
battery voltage would be 53.5V with a 5 Amp load and then 58 volts 30
seconds later when 35 amps were charging into the batteries on a 100%
charged battery bank. 

 

Anyone else had an issue like this? Any advice?
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