[RE-wrenches] Conext SW 4024 with bad firmware

[Ray Walters]

I've seen  similar weirdness with many systems of various brands. The=20
issue seems to be having the generator shutting down while still under=20
load, with as you noted, the frequency and voltage dropping, and the=20
inverter not transferring quick enough.
Basically I suggest to my customers having similar problems to:
A) First, wait for the charge rate to come down, then
B) shut down any other large loads, (ie wait for the water pump to=20
finish pumping) then
C) manually switch the generator Breaker off,  which allows a cleaner,=20
quicker transfer.

Some generators have a cool down period after being signaled to shut=20
off, which solves the problem, too.  Having auto control just shut down=20
the generator hard under load is always going to be rough. I wouldn't=20
blame it all on Schneider, although it sounds like in your case the=20
Conext is extending the low frequency time period, and making it even worse.
A relay might fix the problem too: first have the relay transfer the=20
loads, and then send the signal to shut down the generator after.

Besides the firmware issue, I think you're noticing this problem more,=20
because of all the new arc fault junk in the house.  IMHO, arc fault=20
shouldn't even be required on off grid systems with less than 70 amps=20
capacity.  Unless they've recently changed the UL testing, arc fault=20
breakers need a min of 70 amp to even work properly.  Of course they're=20
annoyingly easy to trip when the frequency and voltage get weird, so off=20
grid all those arc fault breakers are Not going to trip when they=20
should, but Will trip when they shouldn't. More waste of time and money=20
off grid.  Again, just my opinion.

R.Ray Walters
CTO, Solarray, Inc
Nabcep Certified PV Installer,
Licensed Master Electrician
Solar Design Engineer
303 505-8760

On 12/29/2016 12:27 PM, Lou Russo wrote:
> Wrenches,
>
> I recently installed a Schneider Conext SW 4024, Schnieder's DC=20
> Distribution panel, AC Distribution panel, SCP, and the AGS. It was to=20
> be a straightforward inverter swap, Xantrex 4024 to the Conext SW=20
> setup. The actual installation went fine. I did switch over the house=20
> wiring from 120 to 240  as well as the diesel genset.
>
> After a steep learning curve with the client all seemed well. 1 week=20
> later she called and says the power behaves oddly as the generator is=20
> shutting down. Symptoms are some arc fault breakers trip and the=20
> compressor on her fridge sounds like its bogging down. I make the 45=20
> minute drive out and started my search. This is a site with 3=20
> buildings on 3 acres. I double checked all my wiring at the inverter,=20
> then moved onto the various buildings checking for redundant neutral=20
> to grounds, proper bonding, etc=E2=80=A6 Surprisingly although not great =

> workmanship everything is where it is supposed to be. I decided to=20
> give the AC input on the inverter it's own dedicated neutral as at=20
> this point I was reaching for straws and the installation manual was=20
> unclear about this detail. Still nothing. A call to Schnieder=20
> confirmed that there was no setting I was missing.
>
> I placed another call to Schnieder tech support. They did and have=20
> continued to answer the phone promptly. It did take a bit of chasing=20
> them but I finally got a answer that there Level 3 folks can reproduce=20
> the error. The inverter is following the frequency of the genset as it=20
> winds down down to 40hrtz. This is after the AC transfer inside the=20
> inverter has happened. During the cool down period everything is fine.=20
> This happens as the genset is actual shutting off and spinning down to=20
> a stop. They say this a firmware issue and that it will take months to=20
> push out as is needs to be UL listed. In the meantime I have a pissed=20
> off client, her oven went belly up on the low frequency voltage, there=20
> is concern about possible unseen damage to her new water pump, and I=20
>  wasted countless hours of my own time attempting to make the=20
> situation right. All of this due to a firmware that was released with=20
> a fatal flaw and can not be changed for months.
>
> I am extremely disappointed in Schneider. I have been hesitant use=20
> them over the years as I was still scarred from the Xantrex days. My=20
> =E2=80=9Cbeta=E2=80=9D test went will with a early version I installed 2 =
years ago so=20
> I figured it was a safe move. Obviously I was wrong. Lesson learned=20
> stick with Outback and SMA.
>
> So I have 2 questions for the list.
>
> 1.Has anybody else on the list seen this issue and corrected it=20
> regardless of the firmware? I have installed one other conext sw about=20
> 2 years ago when it first came out. The setup is very similar except=20
> that it is 48V and has a very old firmware. I went out to this old=20
> site to confirm all is well and it is fine.
>
> 2.Does anybody have a good contact at Schneider that could be of help?=20
> I tried to contact Sandra Herrera as she was a great help years ago,=20
> but her phone number no longer works.
>
> 3.Does anybody have an old version of the Conext firmware lying around=20
> they could point me to? The website does not seem to have old versions.
>
> Any input is greatly appreciated!
>
> Schnieder, if you have a presence here contact me.
>
>
> Aloha,
>
> Lou Russo
> lou at spreesolarsystems.com <mailto:lou at spreesolarsystems.com>
> 440 345 6762
> Spree Solar Systems LLC
> CT-34322
>
>
>
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