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I kinda remember running into something like this a few years ago.. Turned out it was the Flexnet DC throwing curve balls to the system.. Flexnet does not play nice with LiFePo4.</div>
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db</div>
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<div id="divRplyFwdMsg" dir="ltr"><font face="Calibri, sans-serif" style="font-size:11pt" color="#000000"><b>From:</b> RE-wrenches <re-wrenches-bounces@lists.re-wrenches.org> on behalf of Amos Post via RE-wrenches <re-wrenches@lists.re-wrenches.org><br>
<b>Sent:</b> Thursday, May 15, 2025 10:24 AM<br>
<b>To:</b> RE-wrenches <re-wrenches@lists.re-wrenches.org><br>
<b>Cc:</b> Amos Post <integrityenergy101@gmail.com><br>
<b>Subject:</b> Re: [RE-wrenches] String fuse blown</font>
<div> </div>
</div>
<div class="" style="word-wrap:break-word; line-break:after-white-space">Hey all,
<div class=""><br class="">
</div>
<div class="">To close the loop on this, I doesn\u2019t look like its a \u201cPower Save\u201d setting as those are available on Grid-Tied FX\u2019s. I went yesterday and confirmed that just Inverter #2 is pushing power when grid-tied ( 21A at 120V is what I tested at the time),
however both start inverting (indicated by green LED) when grid-goes down. But it seems to be functioning like the Power Save modes and shutting down Inverter #1 when grid-tied. </div>
<div class=""><br class="">
</div>
<div class="">My best guess is since the array is only 4.2KW and a shallow roof and never really hitting that 4.2KW peak (2.0-3.0KW typical on a sunny day), it\u2019s only running the power through 1 of the inverters because it only needs to run 1. There are no
errors, or warnings on Inverter 1, and what\u2019s weird is even when I switch the inverter ports on the Hub (swap 1 and 2), Inverter 2 is still the only one that\u2019s inverting typically. The exception was when I was testing I shut off grid power for a few minutes
to test the backup function, during which the batteries did an absorb charge. When I reconnected the grid the inverters started to sell some of that battery power(for a minute), along with the PV, down to the sell voltage. Then once the voltage leveled out,
inverter #1 went to sleep again.</div>
<div class=""><br class="">
</div>
<div class="">If this was Myth Busters I would say \u201cPlausible\u201d because I\u2019m not really sure\u2026 :)</div>
<div class=""><br class="">
</div>
<div class="">Thanks for your brains!</div>
<div class="">Amos</div>
<div class=""><br class="">
</div>
<div class=""><br class="">
</div>
<div class="">
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<blockquote type="cite" class="">
<div class="">On May 12, 2025, at 12:53 PM, Amos Post <<a href="mailto:integrityenergy101@gmail.com" class="">integrityenergy101@gmail.com</a>> wrote:</div>
<br class="x_Apple-interchange-newline">
<div class="">
<div class="" style="word-wrap:break-word; line-break:after-white-space">Oh I forgot to mention the inverters are side x side on 2 individual Panels\u2026.<br class="">
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<blockquote type="cite" class="">
<div class="">On May 12, 2025, at 12:48 PM, jay via RE-wrenches <<a href="mailto:re-wrenches@lists.re-wrenches.org" class="">re-wrenches@lists.re-wrenches.org</a>> wrote:</div>
<br class="x_Apple-interchange-newline">
<div class="">
<div class="" style="line-break:after-white-space">good point.
<div class="">For GT OB systems I have removed the side screens for better air flow and I\u2019ve also taken the covers off and used external fans to cool them.</div>
<div class=""><br class="">
</div>
<div class="">They just were not designed to run anywhere near rated capacity for long periods of time, they don\u2019t have enough air cooling.<br id="x_lineBreakAtBeginningOfMessage" class="">
<div class=""><br class="">
<blockquote type="cite" class="">
<div class="">On May 12, 2025, at 10:41\u202fAM, Ray Walters via RE-wrenches <<a href="mailto:re-wrenches@lists.re-wrenches.org" class="">re-wrenches@lists.re-wrenches.org</a>> wrote:</div>
<br class="x_Apple-interchange-newline">
<div class="">
<div class="">
<p class="">Is inverter 2 on top? The top inverter in an Outback dual stack always runs hotter, because the heat from the bottom inverter is adding to its own heat. I used to see that consistently cause board failures on the top inverter more often, if the
whole system was running close to capacity.</p>
<p class="">Ray Walters <br class="">
</p>
<div class="x_moz-cite-prefix">On 5/12/2025 7:56 AM, Amos Post via RE-wrenches wrote:<br class="">
</div>
<blockquote type="cite" class="">UPDATE:
<div class=""><br class="">
</div>
<div class="">So far so good and since replacing the fuse holder, fuse #3 has not blown again.</div>
<div class=""><br class="">
</div>
<div class="">ANOTHER ISSUE:</div>
<div class=""><br class="">
</div>
<div class=""><b class="">Inverter 2 runs hotter than inverter 1.</b> Reminder this is grid-tied system with 2-GVFX3648\u2019s in series for 120/240V. The fan on inverter #2 had malfunctioned, but I was able to replace it and get that going again. Even with
the replaced fan, inverter #2 is still running noticeably hotter. My understanding is that both inverters in this system are essentially \u201cMasters\u201d, since this is grid-tied. Shouldn\u2019t the load/generation be split between the two and hence they run equally
as hot? I did check the stacking and they were both set to \u201cMaster\u201d which is I think what they recommended for grid-tie. I tried switching the ports on the Hub that they are plugged into to see if that would change anything, but no change. I did also noticed
while I was there last week that while both inverters had the solid yellow \u201cAC IN\u201d light on, inverter #2\u2019s green \u201cInverter\u201d light was always on, while inverter #1\u2019s green \u201cInverter\u201d seemed to come and go\u2026</div>
<div class=""><br class="">
</div>
<div class="">Any ideas?</div>
<div class=""><br class="">
</div>
<div class="">Thanks as always,</div>
<div class="">Amos</div>
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</div>
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<blockquote type="cite" class="">
<div class="">On Apr 15, 2025, at 8:40 AM, Amos Post <<a href="mailto:integrityenergy101@gmail.com" class="x_moz-txt-link-freetext">integrityenergy101@gmail.com</a>> wrote:</div>
<br class="x_Apple-interchange-newline">
<div class="">
<div class="" style="word-wrap:break-word; line-break:after-white-space">Hi all,
<div class=""><br class="">
</div>
<div class="">I decided to start with the simple stuff. While I don\u2019t have a string curve tester (I should have one), yesterday I tested strings 1,2,3 individually under load. String 3 is the one that\u2019s been blowing the fuse. I did not test strings 4-6 which
are on a separate charge controller and combiner. Here are the results:</div>
<div class=""><br class="">
</div>
<div class="">String 1- 7.1A at 76V</div>
<div class="">String 2- 7.77Aat 79V</div>
<div class="">String 3-7.13A at 78.3V</div>
<div class=""><br class="">
</div>
<div class="">I did notice that the second charge controller with strings 4-6 was running about 100watts more (1800w vs 1700w). The conditions were clear blue skies. I replaced the fuse holder and fuse. If it blows again I\u2019ll try switching strings to see
if it follows\u2026</div>
<div class=""><br class="">
</div>
<div class="">Thanks for your feedback and I\u2019ll keep ya\u2019ll posted.</div>
<div class=""><br class="">
</div>
<div class="">Amos</div>
<div class=""><br class="">
</div>
<div class=""><br class="">
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<blockquote type="cite" class="">
<div class="">On Apr 11, 2025, at 4:07 PM, Jerry Shafer via RE-wrenches <<a href="mailto:re-wrenches@lists.re-wrenches.org" class="x_moz-txt-link-freetext">re-wrenches@lists.re-wrenches.org</a>> wrote:</div>
<br class="x_Apple-interchange-newline">
<div class="">
<p dir="ltr" class="">Wrenches, Amos, blowing of a 15 amp fuse is not a ghost in the machine, it is an actual issue no way around it, shorted modules, shorted diodes, in most cases it's a home run, way back when USE-2 white wure was failing and would crack
and break off mostly this would result in a GFI trip. The fuse is blowing because of over current and a single string of your vintage will max out at far less than 10 amps but the other two strings will back feed this fuse with close to 20 then pop.<br class="">
Sharp had module failures resulting in cell shorts, look very close there. I have inspected arrays with extreme exposure differences, this will effect performance but should not pop a fuse. Do you have a module string curve tester, this very well may show an
issue of the string but eyes on the array is required to located the cause.<br class="">
I have seen nails through wires, conduit, racking in contact with the back of the module but this will trip the GFI breaker not the string fuse.<br class="">
Fun times. </p>
<br class="">
<div class="x_gmail_quote x_gmail_quote_container">
<div dir="ltr" class="x_gmail_attr">On Fri, Apr 11, 2025, 12:49\u202fPM david quattro via RE-wrenches <<a href="mailto:re-wrenches@lists.re-wrenches.org" class="x_moz-txt-link-freetext">re-wrenches@lists.re-wrenches.org</a>> wrote:<br class="">
</div>
<blockquote class="x_gmail_quote" style="margin:0 0 0 .8ex; border-left:1px #ccc solid; padding-left:1ex">
<div dir="auto" class="">One time I had similar, but different problem: 1 Amp ground fault fuse consistently blowing, sometimes after 1 day sometimes after weeks/months. I tried everything - replaced home runs, checked VOC, VMP, swapped DC input into a different
inverter, etc. it kept coming back to this one string. I checked every module VOC, ISC, every connection, no pinched wires, no discernible problem, but fuse blowing.</div>
<div dir="auto" class=""> Luckily it was a medium size commercial job (on a fire station) so I was able to scatter all the modules of this suspect string all over the roof, and carefully track where I had put them. That\u2019s when the problem went away and never
came back..\U0001f602</div>
<div dir="auto" class=""> Best I could figure was a slight manufacturing error that had a compounding/cumulative effect. So once I got those consecutive serial numbers away from each other no more problem. Either that or the fire chief was fucking with me
and he was burning out the fuses, which I doubt </div>
<div dir="auto" class=""><br class="">
</div>
<div dir="auto" class=""><br class="">
</div>
<div class=""><br class="">
<div class="x_gmail_quote">
<div dir="ltr" class="x_gmail_attr">On Fri, Apr 11, 2025 at 8:05\u202fAM Mac Lewis via RE-wrenches <<a href="mailto:re-wrenches@lists.re-wrenches.org" target="_blank" rel="noreferrer" class="x_moz-txt-link-freetext">re-wrenches@lists.re-wrenches.org</a>> wrote:<br class="">
</div>
<blockquote class="x_gmail_quote" style="margin:0px 0px 0px 0.8ex; border-left-width:1px; border-left-style:solid; padding-left:1ex; border-left-color:rgb(204,204,204)">
<div dir="ltr" class="">Hello Amos,<br class="">
<div class=""><br class="">
</div>
<div class="">Have you checked for voltage imbalance for each string? If you have a bad diode, that string may run low on voltage and be trying to send current toward the weak string (this is the reason you have these breakers). I'd run each string independently
and see what Vmp is. If you are missing some voltage that may be a clue. You can also independently clamp each string during operation.</div>
<div class=""><br class="">
</div>
<div class="">I like IR cameras for this type of thing. It may just be a bad connection, heat build up, fuse holder issue.</div>
<div class=""><br class="">
</div>
<div class="">Let us know what you find out</div>
</div>
<br class="">
<div class="x_gmail_quote">
<div dir="ltr" class="x_gmail_attr">On Fri, Apr 11, 2025 at 8:07\u202fAM Amos Post via RE-wrenches <<a href="mailto:re-wrenches@lists.re-wrenches.org" target="_blank" rel="noreferrer" class="x_moz-txt-link-freetext">re-wrenches@lists.re-wrenches.org</a>> wrote:<br class="">
</div>
<blockquote class="x_gmail_quote" style="margin:0px 0px 0px 0.8ex; border-left-width:1px; border-left-style:solid; padding-left:1ex; border-left-color:rgb(204,204,204)">
<div class="">Hi Wrenches,
<div class=""><br class="">
</div>
<div class="">I have a bit of a puzzler that I\u2019m trying to get sorted out. I\u2019ve been servicing a Grid-Tied Battery Backup system that\u2019s about 17-18 years old. The system comprises of 2-GVFX3648s in series, with 2-MX60(at least I think they are 60s) CC\u2019s.
Each CC has 3 strings of 3 tied to it, and each string has a 15A in-line 600V fuse. The modules are I believe are like 230/240Watt 60 cell modules (sorry I don\u2019t have pictures/specifics). We replaced the flooded batteries with AGMs about a year and a half
ago. </div>
<div class=""><br class="">
</div>
<div class="">The situation is one of the 15A string fuses keeps blowing. It\u2019s now happened 3 times and its the same fuse every time. First we just replaced the fuse and under the surge/lightning assumption. Fuse blew again. Then I thought I found the culprit.
The #6 PV output from the combiner to the PV input breaker for the CC was a bit darkened and very warm to the touch when I replaced the fuse the first time. So I though maybe it was a loose connection on that lug and that caused everything to heat up and
eventually blow the fuse. I cut and stripped the wire back and cleaned the lug and re-seated the wire in the lug. Fuse blew again within a few months time. I then checked the Junction box on the roof where the USE-2 wire connects to THHN, and did a visual
inspection of all the wiring on the roof. All of the Jbox connections and everything on the roof \u201clooked\u201d ok. I have also check all of the connections inside the Outback DC load center, and they look ok. Fuse replaced 3rd time and then it blew again. </div>
<div class=""><br class="">
</div>
<div class="">Before I take all of the panels off the rack, check panels, re-check string wiring on the roof, is there anything else I should be checking? Seems like that warm wire in the Combiner box is telling me something but I can\u2019t figure out what...I
believe this is a new problem in the last 2-3 years but we are not 100% sure when the problem first came up\u2026</div>
<div class=""><br class="">
</div>
<div class="">As always, thanks for your help/ suggestions!</div>
<div class="">Amos</div>
<div class=""><br class="">
</div>
<div class=""><br class="">
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solo sé que no sé nada." </font><span class="" style="font-weight:700; font-family:arial; color:rgb(104,104,104)"><font face="'times new roman', serif" class="" style="font-family:"times new roman",serif; color:rgb(104,104,104)">-Sócrates</font></span></span></span></font></p>
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