Trace charger [RE-wrenches]

[Tom Elliot]

Chuck,

Is the generator a gasoline type and has it ever run out of gas while
charging?  My first clue to a problem with my 4024 came when the charger had
a problem.  In my case it was with fan control but if there are damaged FETs
in the unit and the transformers the FETs control are synched to incoming
gen power the problem could be internal to the Trace.

I know I tend to sound like a broken record on this but my curiousity hasn't
been satisfied by Trace and I'd love to either prove or disprove my theories
on this through other real-world experiences.  If you can put an o-scope on
the inverter output and check signal and spectrum at different loads it
would be interesting to see the results.

Tom Elliot
Guffey Energy Works
Solar Energy Education
http://www.wagonmaker.com


----- Original Message -----
From: "Chuck Heath, SunPower" <sunpwr at jps.net>
To: <RE-wrenches at topica.com>
Sent: Wednesday, July 12, 2000 8:48 AM
Subject: Trace charger [RE-wrenches]


> Client reported charger of a SW 4024 (v. 4.01) not working properly. Site
> visit confirmed this. Only charging source is a Kohler 12 RY generator,
> re-wired for 120 VAC (12 kW before altitude derating). Battery is type
> 85-25 two-volt cells, 1270 AH @ 20 hr. discharge rate. System installed
> in 1998.
>
> Symptoms: Trace sees AC-2 Good from Kohler, goes into Bulk charging for
> only 30-35 seconds, then drops out of Bulk and back to inverting for 10
> seconds until cycle repeats. Kohler voltage is a steady 117-118 VAC
> whether under load or not. Trace reports Kohler frequency as rock-solid
> 60 cps.
>
> After nearly 6 hours generator runtime, was able to raise battery voltage
> from 26.8 to 27.2 VDC - not nearly enough. At-rest battery voltage was
> 24.9 VDC. Set Gen Amps AC (Menu #11) and Set Max Charge Amps AC (Menu
> #10) are both at 35 Amps AC. Lower values did not change results, nor did
> changing Set Float Voltage (27.1 VDC) to match Set Bulk Voltage setting
> (Menu #10) of 29.8 VDC.
>
> Bryan at Trace Tech Support (<tracetech at traceengineering.com> and
> telephone extension 2203) recommended switching Kohler output from SW Gen
> Input to SW Grid Input, AC-1.
>
> Did that. Result was the same, except for causing a Generator Start error
> which shut down the Kohler in less than a minute from RY 7. Running the
> Kohler using its "Run" instead of the "Auto" switch position caused the
> same cycling of 30-35 sec. Bulk charging, 10 sec. of inverting, then back
> to Bulk charging. Ambient air temp was 68 upon arrival, 86 degrees F. by
> early afternoon. Trace internal fan worked just fine.
>
> All Trace menu settings were checked at least twice and found to be
> correct.
> Did not try using the default menu settings.
>
> Ideas?
>
> Chuck Heath "Plugging into Sunshine since 1989"
> Big Oak Flat CA
> sunpwr at jps.net
> 209 962-7012
>
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