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Finally have my EG4 system connected but dealing with startup issues

coolcat

New Member
Joined
Nov 5, 2022
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45
After months of delays from my utility company we finally got our EG4 system connected yesterday. We are still waiting on a meter upgrade so any exported power is not going to be credited but with these batteries I’m hoping to stop as much export as possible anyway. At this point we aren’t even producing solar power, I believe there's an issue with how the GridBOSS is configured for AC coupling. Getting that going has been my primary goal since the electrician left. Secondarily but equally important is that for some reason my system seems to be stuck in a battery power only mode.

My system consists of a GridBOSS with my entire house on the backed up loads breaker, a FlexBOSS21, five indoor Wallmount batteries and our existing Enphase AC coupled solar system. I went through an all night ordeal getting everything configured and running, had several faults and warnings and ended up going back into a blackout to restart it all.

The grid is on and I've got grid voltage on the Eaton grid breaker and non-backup load lugs (which are unused). The inverter is on and powering the house from the batteries and its voltage is on the backup load breaker in the GridBOSS. Despite the grid being on the GridBOSS's "Grid" light is off, only its "Hybrid" light is on. In the EG4 Monitor center the system shows voltage on the grid but no power from it, that voltage matches my manual reading. Interestingly the mobile app shows zeroes instead of the voltage and frequency readings that are displayed in the web portal. I have tried cycling the grid breaker off and on with no change.

I have Smart Port 2 configured for AC Coupled solar input. It's frustrating that there are so few configuration options, it's only "enable" or "disable" and then an SOC start and SOC end setting and some time settings. The tool tip on the SOC end says to set it to 101 which I have done. I think I may not understand these parameters right, I initially set SOC start at 1% thinking that would keep the port on at all times but now I'm thinking it should actually be at 100% because maybe it's a "lower than this we turn on" setting instead of a "higher than this we turn on". If the sun is out I want power. Every time I try to change the parameter now I get an "operation failed error code 3." I disabled it to try again and I still get the same error. My Enphase system has started sending me red alerts because it has now been powered down for over 24 hours. There's no voltage on the smart port breaker.

At this point unless I can get some better guidance I am planning to do another blackout. I'm hoping that a full restart of the system will get the grid interconnect in the GridBOSS working and hopefully maybe it will also get the AC coupling running. I just need it to activate these two relays essentially is my understanding. Any advice is welcomed.
 
I have seen error code 3 when I tried to set a value that would not work, like start above end, or the same. I have AC coupled started to be 95.

Is the GB on the latest firmware? I also have had the grid light go off when the grid was clearly present and functioning. Annoying, but since I can verify with the cloud portal, Home Assistant or the mobile app with direct connection, I don't pay much attention to the LEDs
 
Thanks for the reply. I figured the same thing with the error code 3 so I've tried multiple different values, 10, 50, 90,100, nothing will take. I even disabled the AC coupling to see if that would let me change it with no luck. I'm about to restart the whole system and see if that helps.

Both GB and FB are on the latest firmware. That was one of the things late last night (early this morning?) that took a while before I could get the power back up. If grid power was being passed through, even if only to my AC coupled solar, I'd be happy. But it seems that even though the GB sees that the power is there it isn't closing the relay to let it in.
 
I've got updates! I prepared to power down by first putting the inverter into Standby mode. To my surprise the relay clicked and the GB switched over to grid power! So now the inverter is in standby and the house is powered from the grid. Then I went into the smart port settings and with the inverter in standby the GB seems to be more willing to cooperate! I let me do 10 so I did 90, it let me do that so I tried 99, no go, 98, no go, 97 the same but it let me do 96%! As soon as I clicked "enable" the relay clicked and the smart port is on and my solar is coming online! Woohoo! With the End SOC at 101 I believe the port should never shut off which is exactly what I want. My trouble getting this up last night must have been that the batteries were at 100%. I've now drained them down to about 72% so they were able to trigger the Start SOC once I was able to adjust it.
 
Now my new problem is that the system isn't charging the batteries. With my solar now up and running I'm producing 10kW and it is not being used to charge the batteries back up. Man, I've got so much to learn about how to configure this system. I really wish there were better training resources for this.
 
Check the working mode/battery setting. You want to be in self consume or AC Charge and the limit, SoC or Volt, needs to be higher than the batteries current state
 
It is set to self consume and the limit SOC is set to 101%. Still not charging. Since we're running on the grid and AC tied solar now maybe I'll restart the inverter. Maybe that will help?
 
Well, about 5 minutes later it did start charging! For at least a few minutes the system was able to power the house and sink all of the excess solar production right into the batteries! Woohoo!

Problem is that when I stopped dancing and celebrating I decided to try and button some things up and when I went to put the internal cover into the inverter I accidentally knocked the battery breaker off! daggumit. It's been a few minutes and the "Normal" light on the inverter is still flashing instead of solid. Ugh, I'm a dummy. Should have just taken the W and walked away.
 
The system has been up and running now for over a full day in self consumption mode. Overnight the batteries only dropped to 33% SOC. Peak SOC during the day was about 95%. This was with only four of our five batteries in the system (as I await the arrival of an RS232 update cable to finish the battery firmware update). So far I’m ecstatic! I find myself wishing that the info in the Monitor portal was more clear and customizable. For some reason even though there’s a graph line called “consumption” it doesn’t appear to be showing our consumption, it just kind of follows the battery discharge while running on battery power and then hits 0 and stays there while running on solar. Then there’s a graph line called “AC Couple/Generator” that is just always zero even though in the bar chart below it the “AC Couple/Generator” bar shows that we produced almost 69kWh today.

I’m currently chasing down some kind of gremlin that has caused our Sense device to stop working properly. When the system came back online it wasn’t showing anything. I was able to fix the solar production sensing by reversing the solar CTs but the same did not help on the consumption side. I like having it as a parallel way to monitor what’s happening. I’ve actually been using it as my primary way to see my solar production since the beginning of this whole journey back in 2019. While it has a lot of wasted potential it’s interface is still much better than what Enphase offers and it has spoiled me I think because I keep wishing the EG4 system was more like Sense’s interface.

One thing I had noticed during the time we were running on the unexplained “battery only” mode for a while yesterday was that every time the air conditioner kicked on all of the APC UPS batteries in my house would chirp in complaint for a few seconds. I’m thinking maybe a soft starter for the AC compressor is in order. I’ve never needed it to run the HVAC system even when powering the house with my portable generator (which has a much lower output capacity than the FlexBOSS21) but if things are complaining then I’ll have to consider it.
 
Check the working mode/battery setting. You want to be in self consume or AC Charge and the limit, SoC or Volt, needs to be higher than the batteries current state
I have been searching everywhere for a detailed pre-startup to complete startup/setup information. I have yet to find anything. I do not see any replies to help you resolve your issues; I've been lurking in the shadows trying to prepare to startup my lifepower4 v2 batteries and FB21. Have you been able to find out the information you needed to resolve your issues?
 
I have been searching everywhere for a detailed pre-startup to complete startup/setup information. I have yet to find anything. I do not see any replies to help you resolve your issues; I've been lurking in the shadows trying to prepare to startup my lifepower4 v2 batteries and FB21. Have you been able to find out the information you needed to resolve your issues?
We are up and running. It was rough there at the start because our grid was powered on and the GridBOSS turned on before the FlexBOSS21 was configured. I think this thread covers a lot of the steps I went through.

My advice for a fresh startup is:
A) Batteries first! Turn them all on before closing the battery breaker on the inverter.
2) Inverter next! Before turning on the grid or solar power get the inverter fully configured and ready to run based on your system.
d) Grid and/or solar last. In my case that means the GridBOSS. If you don’t have one then adapt accordingly.

If things don’t seem to be going right be prepared for a full shut down to restart the system. I would recommend that you get it working right before you start fully powering the loads. I made the mistake of allowing full grid power through my GridBOSS into the house before anything was set up or configured. Because of that I ended up in a tangled mess. We were even on bypass power for a while.

If you’ve got any questions I can’t guarantee that I’ve got answers but I’ll certainly share anything that I have learned that might help.
 
We are up and running. It was rough there at the start because our grid was powered on and the GridBOSS turned on before the FlexBOSS21 was configured. I think this thread covers a lot of the steps I went through.

My advice for a fresh startup is:
A) Batteries first! Turn them all on before closing the battery breaker on the inverter.
2) Inverter next! Before turning on the grid or solar power get the inverter fully configured and ready to run based on your system.
d) Grid and/or solar last. In my case that means the GridBOSS. If you don’t have one then adapt accordingly.

If things don’t seem to be going right be prepared for a full shut down to restart the system. I would recommend that you get it working right before you start fully powering the loads. I made the mistake of allowing full grid power through my GridBOSS into the house before anything was set up or configured. Because of that I ended up in a tangled mess. We were even on bypass power for a while.

If you’ve got any questions I can’t guarantee that I’ve got answers but I’ll certainly share anything that I have learned that might help.
Thank you for the information, it's very helpful. The struggle I have is how outdated and incomplete the documentation is.
The latest Lifepower4 V2 documentation:

"13. FIRMWARE UPDATES
Always ensure all system components are fully up to date before commissioning the system and that all battery firmware is up to date to support proper closed loop communication.
Please visit https://eg4electronics.com/resources/downloads for the latest firmware."

Update the firmware before you commissioning the system, we're not going to tell you how to do it and, for your convenience, we've provided a link to a page the doesn't exist.

Do you know how to check and update the battery firmware without using the updater that recently came out? I've called EG4 support 3 times, listened to hold music for a total of 40 min, they never picked up. Never experienced this before from a company I've purchased anything from.
 
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Thank you for the information, it's very helpful. The struggle I have is how outdated and incomplete the documentation is.
The latest Lifepower4 V2 documentation:

"13. FIRMWARE UPDATES
Always ensure all system components are fully up to date before commissioning the system and that all battery firmware is up to date to support proper closed loop communication.
Please visit https://eg4electronics.com/resources/downloads for the latest firmware."

Update the firmware before you commissioning the system, we're not going to tell you how to do it and, for your convenience, we've provided a link to a page the doesn't exist.

Do you know how to update the battery firmware with a laptop?
I know how to update the PowerPro/Wallmount batteries, maybe it’s similar for your Lifepowers?

I was sold an RS485 to USB cable along with my batteries. When I went to update the battery firmware I discovered that my batteries have two sets of firmware and both are required. So I had to purchase an RS232 cable as well and wait for it to arrive which caused some delays. If you go to your battery’s product page on EG4’s website the firmware updates should be there and inside the download is a full procedure instruction document that goes through it step by step.

I’m a Mac guy so I had to borrow a Windows laptop in order to do the firmware updates. On top of that no drivers were included with the cables so I had to go out and find them. The drivers on EG4’s website didn’t work. I’m a problem solver and I don’t know what quit means so eventually I found the chipset manufacturer for the cable and then found their website and got drivers direct from them. Reinforced why I dislike Windows but I managed to get through it all.
 
I know how to update the PowerPro/Wallmount batteries, maybe it’s similar for your Lifepowers?

I was sold an RS485 to USB cable along with my batteries. When I went to update the battery firmware I discovered that my batteries have two sets of firmware and both are required. So I had to purchase an RS232 cable as well and wait for it to arrive which caused some delays. If you go to your battery’s product page on EG4’s website the firmware updates should be there and inside the download is a full procedure instruction document that goes through it step by step.

I’m a Mac guy so I had to borrow a Windows laptop in order to do the firmware updates. On top of that no drivers were included with the cables so I had to go out and find them. The drivers on EG4’s website didn’t work. I’m a problem solver and I don’t know what quit means so eventually I found the chipset manufacturer for the cable and then found their website and got drivers direct from them. Reinforced why I dislike Windows but I managed to get through it all.
Thanks again. It looks like you're better off with the batteries you've bought. Ive been through all of the posted documentation for the lifepower4 v2 batteries. Not one document lists the steps to update the firmware but all point to the downloads page that is not there. Cannot find the BMS Tools anywhere on their page.

"The PC software “BMS Tools” provides real-time battery analysis and diagnostics. The battery
cannot communicate with BMS Tools and a closed loop inverter at the same time.
Visit https://eg4electronics.com/resources/downloads to get the latest version of the software. The
file can be located on the downloads page under Software Drivers.
Once the file has been downloaded, unzip the .zip file. Once the file is unzipped, refer to the
included “Connection guide for BMS Tools V1.0. or V2.2.1.pdf” for a walkthrough on installing and
using BMS Tools."

There is also a QR code that links to a youtube video which tells you to go to the download page that doesn't exist. It's like being punked only better.

I guess I'll call back and sit on hold.
 
Thanks again. It looks like you're better off with the batteries you've bought. Ive been through all of the posted documentation for the lifepower4 v2 batteries. Not one document lists the steps to update the firmware but all point to the downloads page that is not there. Cannot find the BMS Tools anywhere on their page.

"The PC software “BMS Tools” provides real-time battery analysis and diagnostics. The battery
cannot communicate with BMS Tools and a closed loop inverter at the same time.
Visit https://eg4electronics.com/resources/downloads to get the latest version of the software. The
file can be located on the downloads page under Software Drivers.
Once the file has been downloaded, unzip the .zip file. Once the file is unzipped, refer to the
included “Connection guide for BMS Tools V1.0. or V2.2.1.pdf” for a walkthrough on installing and
using BMS Tools."

There is also a QR code that links to a youtube video which tells you to go to the download page that doesn't exist. It's like being punked only better.

I guess I'll call back and sit on hold.
BMS Tools is out there. I ended up trying to use it to determine my firmware versions at one point. For sure EG4’s documentation needs a lot of work. Their manuals even directly contradict each other sometimes.

I found this on the “Firmware” section of the Lifepower V2 product page:
 

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