EG4-6500EX-48 Issue

[Quattrohead]

Start flipping breakers, maybe a faulty ceiling fan, something motor ?
I just cannot guess what would cause the voltage to jump around so much without tripping a breaker, showing current on the ground wire or the inverter shutting down for overload.
Like I said before, I can have both water heater and dryer running and then the bastard to start AC compressor kicks on and I still have never seen either inverter drop below 118v. A good working 6548/6500 is a sturdy beast....I love them.

 

[Quattrohead]

Random thought...have you swapped the PV input between the inverters ?
Is one of the arrays near some wiring from the suspect breaker panel upstairs? Induced noise.

 

[Adam De Lay]

I swapped the L1 and L2 at the breaker after the inverters. Voltage is steadier on 2P2 and now there is some voltage variation (less than what I had on 2P2) on 2P1. Further investigation indicates a subpanel located upstairs that was a service panel back in the 50's or 60's is the culprit. If I turn the breaker off for that panel, the voltage stabilizes and the pulsating lights problem goes away. I rewired 90% of this house when I purchased the acreage 12 years ago, never did anything with this panel as it is mainly lighting circuits upstairs and a few downstairs and the upstairs had already been sheet rocked.

I'll keep narrowing it down, the panel will get replaced first. Then keep breaking it down if the problem continues.

Sounds like you're having to go down the rabbit hole that I was, but to my knowledge I wasn't experiencing the voltage fluctuation, just the flickering lights.

 

[NVCYberPro]

As bad as I hate to say it, resolution specialist is farther behind than that. We're 4 to 5 days out at the moment. If today was day three you'll most likely hear from him tomorrow.

@BenFromSignatureSolar

Looks like you are correct - Now awaiting contact from the RMA department.

This is a bit concerning, even more so after reading @Zwy posts. So now my situation looks as if I am now expected to box up the unit (loosing all solar power to my home when I turn the unit off) and I am to mail the unit back. To do so I will either have to wait for a pickup or drive an hour an a half or so to a drop center to send the unit back. When I placed the order I can say that SS was fairly quick in getting it to the delivery service when compared to some but then it still took 18 days. Ordered the 12/23, status changed to shipped 12/23 but label created on 12/27 and arrived 1/10. I guess I can't really complain about that, However if this is what is to be expected then I could possibly be without the unit for 4 - 6 weeks and that is something I just can not do. I am willing to do a CC hold or something and ship the faulty unit back when the other arrives if that is an option @BenFromSignatureSolar.




Hello,

My name is Kaleb, and I am a Resolution Specialist at Signature Solar. Thank you for your time and patience throughout this process! Our team has reviewed your ticket information and we see that you're experiencing issues with your EG4-6500EX Off-Grid inverter. We would like to return this inverter to our facility for further testing and provide a replacement.

Your ticket information has been forwarded to our RMA team so they may begin their next steps in the return process. Please ensure that all the cables and components that came with the unit are returned with the unit. Additional charges may be applied if all original components/cables are not returned. The RMA team will reach out via email with return shipping information. This information may be lost in your spam or junk folder if not in your inbox. Please let us know once the inverter is shipped. Once we receive the inverter, we will ship the replacement right away! Please let us know if you have any questions and thank you very much for your support!

Kaleb B.
Resolution Team
Signature Solar LLC
1130 Como St South
Sulphur Springs, TX 75482
903-441-2090

 

[BenFromSignatureSolar]

@BenFromSignatureSolar

Looks like you are correct - Now awaiting contact from the RMA department.

This is a bit concerning, even more so after reading @Zwy posts. So now my situation looks as if I am now expected to box up the unit (loosing all solar power to my home when I turn the unit off) and I am to mail the unit back. To do so I will either have to wait for a pickup or drive an hour an a half or so to a drop center to send the unit back. When I placed the order I can say that SS was fairly quick in getting it to the delivery service when compared to some but then it still took 18 days. Ordered the 12/23, status changed to shipped 12/23 but label created on 12/27 and arrived 1/10. I guess I can't really complain about that, However if this is what is to be expected then I could possibly be without the unit for 4 - 6 weeks and that is something I just can not do. I am willing to do a CC hold or something and ship the faulty unit back when the other arrives if that is an option @BenFromSignatureSolar.

View attachment 139982


Hello,

My name is Kaleb, and I am a Resolution Specialist at Signature Solar. Thank you for your time and patience throughout this process! Our team has reviewed your ticket information and we see that you're experiencing issues with your EG4-6500EX Off-Grid inverter. We would like to return this inverter to our facility for further testing and provide a replacement.

Your ticket information has been forwarded to our RMA team so they may begin their next steps in the return process. Please ensure that all the cables and components that came with the unit are returned with the unit. Additional charges may be applied if all original components/cables are not returned. The RMA team will reach out via email with return shipping information. This information may be lost in your spam or junk folder if not in your inbox. Please let us know once the inverter is shipped. Once we receive the inverter, we will ship the replacement right away! Please let us know if you have any questions and thank you very much for your support!

Kaleb B.
Resolution Team
Signature Solar LLC
1130 Como St South
Sulphur Springs, TX 75482
903-441-2090

I'll check out your specific case and see what's going on. Give me a bit to walk this down and I'll get back to you.

 

[Zapper77]

I swapped the L1 and L2 at the breaker after the inverters. Voltage is steadier on 2P2 and now there is some voltage variation (less than what I had on 2P2) on 2P1. Further investigation indicates a subpanel located upstairs that was a service panel back in the 50's or 60's is the culprit. If I turn the breaker off for that panel, the voltage stabilizes and the pulsating lights problem goes away.

Bad wiring, breaker or loose connection?

 

[Zwy]

Random thought...have you swapped the PV input between the inverters ?
Is one of the arrays near some wiring from the suspect breaker panel upstairs? Induced noise.

I never see the problem when array is producing. It appears to be on those circuits in that subpanel.

 

[Zwy]

Bad wiring, breaker or loose connection?

Could be any of the above. It's an old fuse panel with 4 15amp fuses in it, looks to be from the late 60's. I ordered a breaker panel that will fit in the space and intend to pull new wire from CL panel to feed it. 30A breaker feeds it in CL. There isn't a ground to this panel, good time to upgrade it. Unfortunately the circuits do not have a EGC, but these are basically just lighting circuits. I'll have to trace the circuits out. Probably some outlets in upstairs, our daughter and son moved out years ago, part of the reason I never did anything with this panel.

Won't see the wire until Monday and the panel on Tuesday or Wednesday. Probably won't get much done until the following weekend. Pulling the wire should be fun but I think I have partial access in a closet under the stairs that only had the sheetrock screwed on and never taped.

 

[NVCYberPro]

I'll check out your specific case and see what's going on. Give me a bit to walk this down and I'll get back to you.

Hi @BenFromSignatureSolar - They gave me the option to pay for the replacement upfront and issue a refund when the defective unit arrives.

 

[Zwy]

Random thought...have you swapped the PV input between the inverters ?
Is one of the arrays near some wiring from the suspect breaker panel upstairs? Induced noise.

I never see the problem when array is producing.

 

[Zwy]

Delete

 

[BenFromSignatureSolar]

Hi @BenFromSignatureSolar - They gave me the option to pay for the replacement upfront and issue a refund when the defective unit arrives.

I assumed that would be the way it would ultimately work out. Easiest way really to get you fixed up and keep your system rolling in the meantime.

 

[donb108]

I never see the problem when array is producing.

Hmm, I'm not very familiar with this inverter, but I assume the array feeds power to the battery, the inverter draws power from the battery, and that power goes to the loads.

When the array is producing (and the problem is not happening), are the batteries close to full charge? Anything unusual happening at the batteries when it happens?

 

[Zwy]

Hmm, I'm not very familiar with this inverter, but I assume the array feeds power to the battery, the inverter draws power from the battery, and that power goes to the loads.

When the array is producing (and the problem is not happening), are the batteries close to full charge? Anything unusual happening at the batteries when it happens?

Nothing unusual. Days like today I pull 8Kw off my 8Kw array all day, run laundry and electric dryer plus recharge from about 50% SOC. Works perfect all day. Even run dishwasher if it needs to run and be close to 100% SOC on batteries at the end of the day.

The SCC puts DC power on the DC bus and the inverter draws from the DC bus. Inverter doesn't care where the DC power comes from.

 

[donb108]

Nothing unusual. Days like today I pull 8Kw off my 8Kw array all day, run laundry and electric dryer plus recharge from about 50% SOC. Works perfect all day. Even run dishwasher if it needs to run and be close to 100% SOC on batteries at the end of the day.

When DC power to the inverter is abundant, all is well. When power is only coming from the battery, not so well. I'm reminded of a car battery when starting the engine, the battery voltage sags a little. I would think that if a massive load was happening, it would be noticeable.

Quick sidebar; when I'm on utility power (i.e. infinite supply), nothing turning on/off is noticeable. If I'm running on a generator, lots of things are noticeable (generator bogs down). Not that that's your issue, just an observation.

That might be a question for SS; is it possible to bog down the inverter?

 

[Zwy]

When DC power to the inverter is abundant, all is well. When power is only coming from the battery, not so well.

Heavy loads seem to be less light pulsation, lighter loads I notice it more. Usually when you see about 300W load on each inverter.

I'm reminded of a car battery when starting the engine, the battery voltage sags a little. I would think that if a massive load was happening, it would be noticeable.

You might see a blink when something like a well pump kicks in. This isn't the same.

Quick sidebar; when I'm on utility power (i.e. infinite supply), nothing turning on/off is noticeable. If I'm running on a generator, lots of things are noticeable (generator bogs down). Not that that's your issue, just an observation.

That might be a question for SS; is it possible to bog down the inverter?

 

[donb108]

I assume we're talking about LED lighting. My understanding of the causes for LED light flickering is voltage variations, frequency changes, and incompatible dimmers. Since you have a voltage issue, I'm guessing you're thinking it's related to voltage swings.

You might see a blink when something like a well pump kicks in. This isn't the same.

Well pumps are usually considered to be large loads, so that kinda rules out the massive load idea.

Usually when you see about 300W load on each inverter.

Oh, that's a pretty light load. Does it still happen if it's dark (array not producing) and the inverter is more loaded down; i.e. dryer, dishwasher, etc. at night?

Heavy loads seem to be less light pulsation, lighter loads I notice it more.

Maybe this answers my previous question. The more heavily it's loaded down, the less it happens. If you load the inverter a lot, does it go away completely?

Hmm, it only happens when the inverters are operating at < 5% of capacity (300 / 6500 x 100=4.6%), and the array is not producing. I'd be tempted to disconnect everything (PV arrays and all loads), and attach a single light bulb to the inverter output; I assume you've already done all sorts of tests to narrow is down. Or, I wonder if that's some special case for the firmware.

 

[Zwy]

I thought I had the problem traced to an old upstairs fuse panel that will get replaced in the next week. I decided to run wire from my CL panel to a few of these circuits so I won't need to run a larger cable to that panel.

I ran new wire to the bedroom switch box for the fan and lights, easy access from backside as there was a sheet rock panel screwed to the wall inside a closet that I never taped for this reason. While twisting the neutrals together, I noticed a slight arc if the lineman's pliers touched the metal of the grounded switch body. Measuring with a DVOM shows 0.5V and 0.5A. Granted it is a parallel path. But the circuits were all off.

I have a 3 pole transfer switch with neutral switched, N-G bond is at the utility meter 100 feet away. Neither CL or house main panel are bonded. One inverter still has the bonding screw in it. I do have a ground rod right at CL and main panel.

I'm somewhat perplexed why I'm seeing the voltage on the Neutral with that circuit off. It run directly back to CL panel.

I also have the light flicker on occasion even with the upstairs panel completely off. I don't think it is causing the flicker.

 

[Zapper77]

I noticed a slight arc if the lineman's pliers touched the metal of the grounded switch body. Measuring with a DVOM shows 0.5V and 0.5A. Granted it is a parallel path. But the circuits were all off.

Shared neutral with another breaker and the ground provides a better path to the main panel. (Wire maybe a 12/3 with ground, the black and red share the same neutral but still operate independently)

 

[Zapper77]

I thought I had the problem traced to an old upstairs fuse panel that will get replaced in the next week

You may have a neutral splice that has a "failing" connection. Could be anything from loose screw at a receptacle, crimp/twist cap or corrosion.