Schneider Setup support needed

[OffGridMike]

I need some help. I have been working on my off-grid solar setup for almost 3 years now. My cabin came with an undersized system that ran the propane generator to the ground. After upgrading the batteries, solar panels, charge controller, and replacing the generator, I am stuck with some persistent issues that I believe can be fixed with settings in my Schneider System Control Panel. But I am struggling to find the right settings. I am looking for someone I can connect with for a live/virtual consultation.
I am near the Gifford Pinchot National Forest/Mt. St. Helens in Washington State.

My current equipment:
Xantrex XW 6068 hybrid 120/240 60 inverter/charger
Xantrex XW System Control Panel
Xantrex XW Automatic Generator Start
Conext MPPT 60 150 solar charge controller
4x 48V100ah EG4 LiFePower4 batteries
connected with the EG4 communications hub to an Insight Home communications hub
12x Canadian Solar CS6R-390MS-HL panels in 4 series of 3
Brand new Kohler 12RES propane generator

My current issues:
System overvoltage - when I connect the data cable from the batteries to the SCP (through the EG4 communications hub or direct) it gets an overvoltage fault whenever it reaches 100% SOC. If I charge based on voltage, I have been able to get settings to avoid the overvoltage faults.
Generator start - I just had a new generator installed, replacing the previous generator of the same model. The previous generator worked with the AGS without issue, but the new one does not seem to start from the control panel. The guys that installed the generator think it is an issue with the Schneider system and not the generator.
Insight Home - I seem to have limited functionality with my app and web portal. For example, I stopped getting live updates in the app several months ago. When I am connected to the local network I have a lot more functionality than when connecting via the web.
Settings - I am looking to get the SOC working, allowing charging to full without overvoltage. And I want to set up the AGS to kick in at 20% and charge to 40%.

Is this something Schneider support would do? I know this is a DIY forum but I am tired of doing it myself and not getting it working right. LOL. Any suggestions are appreciated.

 

[hwy17]

I have heard that Schneider does not recommend using both an SCP and an Insight together.

Does this overvoltage alarm cause a shutoff or anything? Lifepower4's have this quirk where they only reset their SOC when they hit the alarm, and you do want them to reset regularly. I set my alarm to 55V just so that my Lifepower4 would regularly go into alarm at full charge.

For the generator, see point number one about using the SCP. Maybe your Insight two wire relay is closing but not the SCP. There's only meant to be one of them in charge.

 

[hogback]

I have a 6848xw+ that works with the "gateway" which is mostly an insight facility with old firmware. However I do not attempt to tease out closed loop signals from it. Perhaps verify that you don't have recent firmware, and possibly give up on closed loop. I have the ags which charges from a smidge over "0%" to full. Is there a setting on the ags that allows for timed run time? If so, then perhaps you could charge from near zero for as long as it takes to give you roughly 40%?

 

[OffGridMike]

I have heard that Schneider does not recommend using both an SCP and an Insight together.

Does this overvoltage alarm cause a shutoff or anything? Lifepower4's have this quirk where they only reset their SOC when they hit the alarm, and you do want them to reset regularly. I set my alarm to 55V just so that my Lifepower4 would regularly go into alarm at full charge.

For the generator, see point number one about using the SCP. Maybe your Insight two wire relay is closing but not the SCP. There's only meant to be one of them in charge.

Checking the manual for the Insight Home, it looks like the Conext System Control Panel is a compatible device. I issue that comes to my mind is that many of my parts are older Xantrex models. I cannot find how interchangeable the Conext and Xantrex components are.

 

[OffGridMike]

Does this overvoltage alarm cause a shutoff or anything? Lifepower4's have this quirk where they only reset their SOC when they hit the alarm, and you do want them to reset regularly. I set my alarm to 55V just so that my Lifepower4 would regularly go into alarm at full charge.

The over-voltage fault happens in the XW inverter and causes a fault which needs to be manually cleared. The fault shuts off power, which shuts off internet, so it needs to be cleared/reset on-site. I have this system partly to maintain power while I am not there, but it continues to shut off when the batteries reach 100% SOC.
I am not familiar with an alarm on the LiFePower4 battery. Or why I would want them to reset their SOC. I assumed the SOC was like a fuel gauge that went up and down from 0% to 100% but did not need to be maintained to keep it accurate.

 

[400bird]

I know you said you were tired of working on it yourself, but no Schneider won't do your set up and I'm too far to drive over and help out, so I'll offer my advice

Or why I would want them to reset their SOC. I assumed the SOC was like a fuel gauge that went up and down from 0% to 100% but did not need to be maintained to keep it accurate.

You definitely do need to reset the SOC to keep it accurate. One could get pretty far into the weeds to explain this, but the simple version is just to know that the SOC drifts and becomes inaccurate over time and needs to be reset/corrected. Hitting the upper limit of the cell voltage is one common method.

I'd ditch the battery communication and program everything for voltage.

Don't forget you have separate charging settings in the MPPTs and XW inverter.

On the generator, can you use the controls on Insight or the SCP to start the generator? If not, there's a wiring issue.
If you can start it manually through the Schneider equipment, it's just a settings adjustment away from working how you want.

 

[OffGridMike]

I know you said you were tired of working on it yourself, but no Schneider won't do your set up and I'm too far to drive over and help out, so I'll offer my advice

You definitely do need to reset the SOC to keep it accurate. One could get pretty far into the weeds to explain this, but the simple version is just to know that the SOC drifts and becomes inaccurate over time and needs to be reset/corrected. Hitting the upper limit of the cell voltage is one common method.

I'd ditch the battery communication and program everything for voltage.

Don't forget you have separate charging settings in the MPPTs and XW inverter.

On the generator, can you use the controls on Insight or the SCP to start the generator? If not, there's a wiring issue.
If you can start it manually through the Schneider equipment, it's just a settings adjustment away from working how you want.

Thanks for the response and sympathizing with me throwing my hands up.

Thinking about why I want to know SOC, it is because I have been having faults at the high end and not having my generator working at the low end. I wanted to know when I needed to shut off the MPPT and when I needed to connect my portable generator. Hopefully, both those situations get fixed quickly.

If I program it all simply off voltage, does that eliminate the need to reset my SOC?

Thanks for the comments about the generator. When the electrician is up in a couple weeks to install the emergency stop that was required for the inspection, I will test different options of starting with the Schneider equipment. If we cannot get it to work, I will have them keep working on the wiring until it does. I found the wiring diagrams and it might be possible the new generator is a different type from the old one.