EG4 6000XP grid voltage jumps all around

[Dustyjeansranch]

Installed a EG4 6000XP with batteries for UPS to the egg incubators. Got grid power wired to it over the weekend. Have spent several days changing settings and no matter what I do it has a relay that clicks, grid voltage jumps anywhere between 48v and 460v. Can not do pass through power or use it to charge the batteries. Attached is a video. I am out of ideas. It works great if just using batteries.

We went with the EG4 6000XP because it does not feed back into the grid. We are using these to power egg incubators as a UPS. Each incubator holds 3,500 eggs. Lost power and incubators shut down before backup generator came online. We are still working on the second house that will have 2- EG4 12000.

Thank you

 

[SunDave]

Hi Dusty,
The video says age restricted, and would require a login to the evil empire (youtube/google).

 

[BentleyJ]

Looks like a flaky connection. Does your multimeter read stable voltage at the input lugs? If so, check the input lug connections inside the inverter connecting to the transfer relay.

 

[ChrisG]

You have L1/L2/N/G running to it, all 4 wires connected from main panel?

 

[Dustyjeansranch]

Looks like a flaky connection. Does your multimeter read stable voltage at the input lugs? If so, check the input lug connections inside the inverter connecting to the transfer relay.

I have consistent voltage between L1 & L2, L1 & neutral, L2 & neutral, L1 & ground, L2 & ground. All were similar except L2 & neutral at 118V. It was consistent though.

The input lugs that connect to the transfer relay, is that in the bottom half that I can access. Or is it in the the top half that has a seal on it over a screw? I am going to open the bottom half right now and check everything, just not to sure on breaking that seal and voiding the warranty.

 

[SunDave]

I believe the factory neutral on those inverters is on the first or second screw from the left on the neutral bar and it goes up into the unit. If you look in there carefully with a flashlight you may see it. You may want to check that it is not loose. Sometimes people try to install their own neutral there, and that messes up the inverters internal neutral connection.

See this thread. Especially the last post. Sounds like yours. Clicking relay and all.

Thread 'EG4 6000XP clicking'

Jun 21, 2024

I have a situation where I was asked to look at a client's relatively new 6000XP. When the generator starts, the unit clicks and clicks and clicks, and if you let it click long enough, it eventually restarts the inverter.

Anyone have any idea why this would make this clicking noise when the Generator is running? It's a quality 12Kw Kohler generator designed for backup power situations.

See the video

• MaikaiLife
• Replies: 12
• Forum: DIY Solar General Discussion

If that isn't it, possibly something like a neutral\ground bond issue. Which I am no expert on, but there are also a lot of threads on this forum about that, and 6000xp inverters.

 

[Dustyjeansranch]

Hi Dusty,
The video says age restricted, and would require a login to the evil empire (youtube/google).

Here is another that is not age restricted. I am scrolling through settings on this video, but the relay clicking is very clear to hear.

 

[ChrisG]

Did you check the 6000xp factory neutral connection mentioned above?

 

[Dustyjeansranch]

Thank you all for the advice. I finally figured out the culprit. The neutral from main panel must have had an internal defect. Meter L1 and L2 to neutral it would meter ok. I swapped L1 and neutral in main panel and then in the inverter (white became L1 and black became neutral) and the issue became self evident in less then a second when it blew sparks through the outer jacket of the wire and smoked. Thankfully the 50 amp beaker in main panel tripped like it should have. Replaced the entire 4/3wg with a 8/3wg and the EG4 6000 worked perfectly. I disconnected everything until I can get the correct gauge wire tomorrow morning. Brand new wire gave me many nights of grief, I feel so stupid for not checking the wire sooner.

 

[SunDave]

Great. You can be mad you didn't find it sooner, or be glad it didn't drag on for weeks. Just saw a post about an EG4 3000 that clicks on and off. I'll link this thread in case the poor neutral connection does the same thing to that model.