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EG4 18KPV - What not to do in parallel

automatikdonn

Becoming Offgrid
Joined
Oct 20, 2021
Messages
467
Location
Texas
So as many of you may know I posted a thread about my neighbor having an issue with his EG4 18k Inverters.

System Information:
60 Panels
2 EG4 18k in parallel
No Battery

Summary of the issue:
When the grid connection is removed, the inverters would begin to provide 400v to the mains input side of the inverters.
The system was professionally installed and all wiring was correct.
The system was reporting everything was fine. No faults or errors were reported. The inverters were being recognized as being in parallel.

Diagnosis:
EG4 got into the system and checked the configurations and found nothing wrong.
EG4 guided us to first check the parallel cable. (Thank you EG4)
We found that the installer had used a cross-over cable that was likely bought from a Box store.
We made a new cable up that followed the proper standards.

Results:
Systems worked as expected. All commisioning tested passed.

Notes:
The inverters likely should catch that a cross over cable was used and not go into parallel mode.
Also, use the correct pinout if you are buying or making an ethernet cable. Not doing so could be dangerous, until a patch is released you could potentially have this problem.

I would like to call out @Markus_EG4. After checking the config, his very first troubleshooting step revealed the issue.

We plugged the factory cable in, executed the same test and it did exactly what it was supposed to.

Other:
Many people have asked why the old thread was deleted. The old thread essentially contained a bunch of speculation while we worked the root cause. In the interest of being as helpful to forum members as possible, this new thread was created to get people the problem and the answer in the OP. We are all here to help each other learn, grow and be the best community on the internet for DIY Solar.

The questions posed in the original thread were helpful as everyone was trying to QUICKLY get to the bottom of the problem. Many thanks to all of you for being so willing to donate your time and your brain to fix problems for essentially what are strangers to you. It's the difference that makes this place great!

Quick Links:

EG4 Response

https://diysolarforum.com/threads/eg4-18k-what-not-to-do-in-parallel.84679/page-6#post-1105159

The elephant in the thread:

These particular inverters could be bad and this issue could be isolated to only them. We do not have other gear to test against, so we cannot confirm the bug. I would ask someone from EG4 to come out and take a look. We are super close and this isn't a big ask IMO.

Before we speculate anymore - short of someone else confirming this bug (I don't have 10K to buy them and test - but will accept donations to do so :ROFLMAO: :ROFLMAO: :ROFLMAO: )

I think we should wait to see how this ends up shaking out. I think this is fair to EG4 and I think this is fair to the commmunity. We don't need to sour anyone without all of the facts. Right now we really only have one fact. These inverters do in fact exhibt this problem.

Signature Solar Response:
https://diysolarforum.com/threads/eg4-18k-what-not-to-do-in-parallel.84679/page-11#post-1105380

Evidence:
Here is a picture of the cable that caused the problem
1717169384717.png

Here is the video of the issue.



New developments:

Here is the pinout

This cable is a specific type of crossover for going from T568A to T568B devices.

The specific pinout allowed the canbus connection to come up, while all the other parallel signals to be crossed.

https://diysolarforum.com/threads/eg4-18kpv-what-not-to-do-in-parallel.84679/page-21#post-1108780
 
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Curious what kind of error checking is being performed on the parallel connection? Having a crossover cable create a 400V condition is kinda poor form.
I hope maybe EG4 or Luxpower could explain what each pin does in the connection. I wouldn't dare speculate at this point.
 
How is the installer considered a professional? Is he licensed? Seems like a massive oversight. How much did he charge for the installation?
I do believe so, but maybe @canadianintruder can paint more color on this.

I think it's possible that he didn't understand that all cables that have an RJ45 connector are not equal.

This mistake resulted in the loss of thousands of dollars in appliances.
 
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Plugged in a LAN cable? Equipment had D*mn well better not blow up if a LAN cable has crossed connections.

Does the inverter documentation even specify that?
This is a great question. I would say that the inverter should have thrown an error - but this probably wasn't something tested in QA. Like @ricardocello said - crossover cables haven't been made for years.
 
I hope maybe EG4 or Luxpower could explain what each pin does in the connection. I wouldn't dare speculate at this point.
The manual implies it is CAN bus because of the DIP switches which presumably add internal 120-ohm resistors at both ends.
They may have additional dedicated lines for parallel control or other sideband signaling on those connectors.
Just guessing.
 
I think we are all curious how the device can even generate 400V in the first place, but maybe we will just have to be patient.
Me too. I think people may have been on the right track with the parallel thing. I don't think anyone saw this one coming. Maybe we will get an answer, maybe not.
I guess if you use what they ship and configure it correctly, there are no problems - so any answer would be awesome, but not required.

I am however willing to bet someone puts this in the QA testing next cycle 😂😂😂

At my real job we make things and customers always find fantastic ways to break our stuff we didn't think of.
 
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Here is the video. It was taken on my cell phone, so sorry. I'm also not a pro video producer.

I'm posting this so people can see what happens when you use a crossover cable.

This video is free and fair use, if you want to clip it, go ahead.

 
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How is the installer considered a professional? Is he licensed? Seems like a massive oversight. How much did he charge for the installation?

Sorry. This really pisses me off. I'm calling bullshit on this dismissive comment. Shame on you. You're faulting an installer for a design flaw that can produce 400VAC where the unit is supposed to provide NO voltage to when grid is not present. Period. That's a UL requirement. It's not magically allowed if the communication cable is miswired.

This situation is really fucked up.

These things better ship with their own fucking straight thru cables. Even if they do, it should be an explicit requirement in the manual to use a straight thru cable. I checked the manual, and there is NO mention of cable type beyond "RJ45."

For the CAN communication with battery, they give some of the pins.

They mention the pins on the CT sensor.

The diagram for the 2X units in parallel makes absolutely no reference to a cable type.

IMHO, EG4 has some liability here for destroying a customer's appliances due to a design flaw. Sure, we can poo poo the installer for grabbing an arguably hard to find cross-over cable, but if using the wrong cable could produce this result, that's just plain fucked up, and EG4/Lux should have a warning in the manual or at least specify the correct cable.

Where in the manual does it say what cable to use?

I have to believe this potential installation fault would violate the UL requirements. UL standards typically cover design/manufacturing requirements and include things like, "you can't do this or that, and you must do these other things, and THIS thing over here must not happen."

In other words, this fucking hunk of shit should not be UL listed.

I can't imagine a manual re-write and/or a firmware update is going to be issued to address this. That's an admission of fault.
 
Sorry. This really pisses me off. I'm calling bullshit on this dismissive comment. Shame on you. You're faulting an installer for a design flaw that can produce 400VAC where the unit is supposed to provide NO voltage to when grid is not present. Period. That's a UL requirement. It's not magically allowed if the communication cable is miswired.

This situation is really fucked up.

These things better ship with their own fucking straight thru cables. Even if they do, it should be an explicit requirement in the manual to use a straight thru cable. I checked the manual, and there is NO mention of cable type beyond "RJ45."

For the CAN communication with battery, they give some of the pins.

They mention the pins on the CT sensor.

The diagram for the 2X units in parallel makes absolutely no reference to a cable type.

IMHO, EG4 has some liability here for destroying a customer's appliances due to a design flaw. Sure, we can poo poo the installer for grabbing an arguably hard to find cross-over cable, but if using the wrong cable could produce this result, that's just plain fucked up, and EG4/Lux should have a warning in the manual or at least specify the correct cable.

Where in the manual does it say what cable to use?

I have to believe this potential installation fault would violate the UL requirements. UL standards typically cover design/manufacturing requirements and include things like, "you can't do this or that, and you must do these other things, and THIS thing over here must not happen."

In other words, this fucking hunk of shit should not be UL listed.

I can't imagine a manual re-write and/or a firmware update is going to be issued to address this. That's an admission of fault.
Ohhh I thought the voltage was being created by a conductor switched in the wiring of the actual inverters. I stand corrected. Yeah, that is not acceptable. I had no clue it was the communication cable.
 
A bit premature there Mr. Eggo?

Nope. I live in the world of aviation where reports of any failure, malfunction, or defect in any product or article manufactured must be made within 24 hours.

It’s not their fault that a bug slipped through.

Huh? I'm completely baffled by this statement. So who's responsible for bugs? Nobody?
 

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