Matthew E's posts

Posted by Matthew E on Jul 16, 2013 10:10 pm

#1 -  Renewable Energy > For Sale > Submersible hydro UW100 for sale
For sale, 12VDC submersible hydro, up to 8A or 100W peak output.�  Small, propeller-driven (prop about the size of an outboard motor prop; unit only about the size of a basketball). Tons of extra parts. Brand new, I just tried it once in our river and realized I don't have sufficient water current for significant output.�  � See details where I bought it: http://www.absak.com/catalog/product_info.php/cPath/33_89_90/products_id/3�  .�  If you're interested, let's talk prices. I'm thinking in the $1200 range. -Matt
 

Posted by Matthew E on Jan 31, 2011 04:43 am

#2 -  Renewable Energy > Technical Discussion: Solar Electric System - Photovoltaic > Re: Xantrex MPPT low output problems
Hey Dave, good question.  I had a lot of discussion with the tech support guy, and he seemed pretty surprised at the symptoms and once we pinned it as an intermittent problem not attributable to any of my other components, he just said it must be malfunctioning and they're going to replace it under warranty.  No indication that they've seen this behavior before- strange.  BUT they've been really helpful & flexible, and willing to do a "scrap in the field" since I'm so far away and it's so hard to get the malfunctioning unit to them.  So I just mail them the serial number & label off the case, and they mail me a new unit!  (hmmm, so maybe this will become my backup, non-MPPT, charge controller? I guess I'd better ask if they want the unit itself whenever I get back to the States!)  You are right that since I've been able to manually set the reference voltage to a value right in the middle of the usual MPPT range I've observed during normal operation, my output is about the same.  So that's a good workaround until I swap for the new unit in ?? months Shocked) .
 

Posted by Matthew E on Jan 27, 2011 05:45 am

#3 -  Renewable Energy > Technical Discussion: Solar Electric System - Photovoltaic > Re: Mixing battery sizes in one battery bank?
Thanks for the tip, Dave!
 

Posted by Matthew E on Jan 23, 2011 03:42 am

#4 -  Renewable Energy > RE General Discussion > Re: What voltage is 100% SOC for an AGM battery?
Here's a really helpful link from the company that manufactured the batteries I'm using (Haze AGM).  They seem to be going by the 12.7V rule, treating AGM the same as other lead-acid batteries. http://www.windsun.com/Batteries/Battery_FAQ.htm#Battery%20Voltages
 

Posted by Matthew E on Jan 23, 2011 03:03 am

#5 -  Renewable Energy > RE General Discussion > Re: appropriate generators for off-grid photovoltaic system
Hey there, that's my situation too!  I've got a 640W 600Ah off-grid PV system, wanting to hook up a generator without frying my Xantrex XW60 MPPT solar charge controller.  Getting nowhere on Xantrex's website, for it all seems to be geared at grid-tied systems, with NO MENTION of us off-grid PV system users. I don't get it.
 

Posted by Matthew E on Jan 23, 2011 02:59 am

#6 -  Renewable Energy > RE General Discussion > Xantrex discontinuing solar?
Hi, I'm researching how to connect a generator to my off-grid PV system which currently has a Xantrex XW60 MPPT charge controller.  Problem is, I can't find ANYTHING on Xantex's website www.xantrex.com indicating that they even produce solar power components.  This is baffling.  There's plenty of grid-tie info, but you'd think they never supported XW systems or off-grid PV systems.  Can anyone enlighten me?
 

Posted by Matthew E on Jan 23, 2011 02:56 am

#7 -  Renewable Energy > Technical Discussion: Other > Re: Help!!!! Wire crimping or soldering?
I'll put in my 2 cents and say I did it soldering, and never again. Now I use a hammer and hammer those lugs on. I have 6 gauge - 000 gauge in my system.  Now my situation is unique, being in a remote location overseas, with very humid conditions.  But when I used flux core solder with a butane torch (keep in mind I only have access to lower quality cables and probably solder too), I had these problems:  I was having to heat up those lugs & wires so long with the torch before the solder would flow that it degraded the copper in the wires (stranded wire), making them brittle (this after trying a monster soldering iron with no success on such large cable & lugs). Also, even after wire-brushing and wiping the finished product of flux residue, I had a huge amount of corrosion, to the point that my wires had reduced to white powder in a matter of months.  Crazy.  So I'm a convinced crimper.  You others are more experienced than me.  Maybe you can enlighten me of whatever I may have been doing wrong...
 

Posted by Matthew E on Jan 11, 2011 11:06 pm

#8 -  Renewable Energy > Technical Discussion: Solar Electric System - Photovoltaic > Re: Xantrex MPPT low output problems
Hey Dave, most nightly rains here feel like monsoons!  And that's during the "dry" season! Shocked)  Well, here's the latest: Xantrex tech support is saying they're going to send me a new unit!  (Of course, send to my U.S. address, then I'll have to get a hand-carry over here who-knows-when!)  But in the mean time, I'm recording comparable output when set on "Manual" (MPPT off) and the reference voltage set to 60.0V (which I might have mentioned was the average reference voltage when the unit was on "Automatic", MPPT on).  So I'm very happy to have a work-around for now, without having to try 2-stage charging.  Of course with my family in the village I never get to "Float" anyway! ;o)  But in 2 days they're back to town and I'll let 'er top off for a good while...  Oh, and about the float timer issue you mentioned, I might mention that in my case, in the mornings when the unit was malfunctioning, the unit was still reading "Bulk", not "Float". Seems to be a different issue, eh? 
 

Posted by Matthew E on Dec 18, 2010 02:22 am

#9 -  Renewable Energy > For Sale > Re: Submersible hydro UW100 for sale
Sorry man, hoping to get more than half for it. It's still brand new...
 

Posted by Matthew E on Dec 18, 2010 02:19 am

#10 -  Renewable Energy > For Sale > Re: Submersible hydro UW100 for sale
Hey Ken, I'm on the Western half of New Guinea, across the border from PNG into the next country...
 

Posted by Matthew E on Dec 18, 2010 02:18 am

#11 -  Renewable Energy > For Sale > Re: Submersible hydro UW100 for sale
Hey guys, thanks for the ideas.  Problem is I don't have any elevation drop, and when I tried constructing a water trough, even with 12' long sides angled like a V toward the unit, I could still only get about half-power.  That was still unrealistic, since frequent heavy rains cause a large fluctuation in river level, as well as sending debris along the river.  I've racked my brain on this one, and I think our river is just too slow I'm convinced.  I took a risk in buying this during one of my (rare) trips back to the U.S., and unfortunately mis-estimated our river velocity.  Who said set up a water wheel and gear it up?  Yeah, possible.  Still have issues with erosion and the large fluctuation of river level (can be 10' overnight).  But I'm enjoying my solar panels in the mean time!  Much less maintenance...
 

Posted by Matthew E on Dec 18, 2010 02:07 am

#12 -  Renewable Energy > Technical Discussion: Solar Electric System - Photovoltaic > Re: Xantrex MPPT low output problems
Hey there, Tom & others. I'm back in the jungle now, messin' with my power system again.  Get this- now I've observed the problems with charging at least twice when the only load all night was my Prosine 1000i Inverter in Powersave mode.  No DC relay connection or other loads.  Since I've also observed some days with no charging problems in this same scenario in the past, and no other variables in the system that I can identify, I've contacted Xantrex to report this as probably an intermittent problem with the charger.  Interestingly, the Xantrex manual does have my symptoms in its troubleshooting section:

Problem: Low panel output. Input and output voltages read about the same.

Possible Cause: Array maximum power point is less than the nominal battery
voltage. The XW SCC is still charging, but cannot charge at Vmpp.

Solution: Check or reconfigure the array.

So one explanation may be that in the morning as the sun is rising and the
MPP is less than the nominal battery voltage (e.g. 5:30am?), the XW hangs in
this state and does not adjust as the PV array output continues to increase. Not sure since I usually start my readings at 6:30am (which is usually up to 50-60V by then), but anyway I'm waiting to hear back from Xantrex. Bummer...
 
 

Posted by Matthew E on Nov 9, 2010 03:14 am

#13 -  Renewable Energy > Technical Discussion: Solar Electric System - Photovoltaic > Re: Xantrex MPPT low output problems
Yeah, man, I'm on that.  But where to get a timer for my 12V freezer?
 

Posted by Matthew E on Nov 9, 2010 03:04 am

#14 -  Renewable Energy > For Sale > Re: Submersible hydro UW100 for sale
Ok, check out my profile. My email address is on there.  Looking forward to your email.  -Matt
 

Posted by Matthew E on Nov 9, 2010 02:59 am

#15 -  Renewable Energy > For Sale > Re: Submersible hydro UW100 for sale
Hey Michael, I've got this unit with me in New Guinea.  I should be able to arrange to get it back to the U.S. if you're in the U.S. and you're serious.  Otherwise, let me know if you're somewhere else in the world.  I'd like to email you the original invoice so you can see how much I paid for everything.  It's still brand new, only been used for a few minutes when I tried it out in my river but the water speed just wasn't fast enough (my estimate of the water speed was wrong).  So when you see how much I paid for it, I figure we can figure out a reasonable price.  I'd rather not post my email address on here, but I might have to. I'll see what I can do.
 

Posted by Matthew E on Oct 13, 2010 06:24 pm

#16 -  Renewable Energy > Technical Discussion: Solar Electric System - Photovoltaic > Re: Xantrex MPPT low output problems
Ahh yes, keeping the fire extinguisher nearby Wink
 

Posted by Matthew E on Oct 9, 2010 02:06 am

#17 -  Renewable Energy > Technical Discussion: Solar Electric System - Photovoltaic > Re: Xantrex MPPT low output problems
Thanks for the encouragement, Dave! 

Where can I get those ferrite beads, and do you snap it on both lines?  Are you thinking I'd try putting it/them on the relay control circuit cable(s)?

Also, re: the inverter, I can run the inverter in "Powersave Mode", which will cause it to go into standby when the load is less than 10W, so I'll try it and make sure it can do that.  Sounds like it'll work well.  In standby, it draws only 1.5W.  Is your concern that with only one leg switched, I'll still have some kind of current flowing in the AC lines?  Please explain.

Looking forward to getting back to the village to test it out...

 

Posted by Matthew E on Oct 6, 2010 03:09 pm

#18 -  Renewable Energy > Technical Discussion: Solar Electric System - Photovoltaic > Re: Xantrex MPPT low output problems
Hi Tom & David,
Thanks for the encouragement! 

Yes, the reason for the relay is to protect my batteries from discharging too low and damaging them or reducing their lifespan.  Yes, the idea is an automated system I can walk away from which will monitor itself to protect the batteries from over-discharge.  The Sundanzer freezer's default (not customizable) low-voltage cutout is 10.8V or 11.8V or something, which may protect the compressor, but still toasts my batteries!  So I want to keep my AGM batteries at or above the 12.2V range (~50% so I've been told), to maximize their lifespan.  Similarly, my Prosine 1000i inverter has a default (not customizable) low-voltage cutout of 10V - big help that is!  Xantrex tech support tells me if I'd sprung for the expensive XW system inverter of course I could customize its low-voltage cutout, but for my small system that extra $3600+ isn't worth it (and they agreed). 

So my plan was to use a DC relay to run all of my loads, powered by the charge controller's Aux output.  Unfortunately, finding a DC relay large enough to run my inverter through was not realistic (Amperage too high), so I opted for using 2 relays: one SSR is 12VDC up to 40A for my DC loads (some 12VDC emergency lighting, 12V freezer, 12V satellite internet system, totaling <=20A altogether); and a second SSR is 220VAC, wired between my inverter 220VAC output and my house 220VAC circuit breaker panel. I haven't tried the AC relay yet (does it need diodes too?), but first trying to work out the kinks with the DC relay.

Tom, there is nothing switching the Aux-to-relay power.  The charge controller itself switches the Aux power on or off based on battery voltage levels.  I'm currently set to "Active Lo", meaning the Aux port is normally powered (sending power to the control circuit of the DC relay, causing it to close).  The charge controller cuts Aux port power (thereby opening the DC relay) when battery bank voltage falls to 12.2V or lower for 5mins or more.  I've tested this scenario, letting my batt bank voltage drop to 12.2, and it operates correctly, cutting power to the relay control circuit until batt voltage returns to 12.4V for 5mins or more.  According to the XW charge controller's instructions, the Aux port can be used to power a relay for this very purpose. But Xantrex tech support tells me "I've never heard of anyone using a setup like this, but it should work."  Well, the XW's instructions (p. 1-8 "Auxiliary Output Functions") indicate this as a primary use of the Aux port!

Xantrex tech support suggested trying a C35 as a load controller if we can't get the DC relay setup to work, but then I still need to figure out how to manage my AC loads.  Who knows, maybe the AC relay won't have these issues! Not going there yet though!

Grounding: sorry, my simple diagram doesn't show that I have a ground running from my charge controller to a ground bus bar, then to ground.  (but not connected to the battery negative, in keeping with the XW instructions)

Relay: Is there a problem with the relay being continuously powered?

Running directly off battery: guys, we're thinking alike here! I will try running the freezer and satellite system straight from the batteries when I'm next in the village.  It's not a good long-term solution, but it will help me isolate the problem (which seems to be some kind of interference caused by the relay, but we'll see).
 
View from my power shed:


Regarding aux port output voltage: again, we're thinking alike! I just made a note to myself to try the aux port output voltage at 5VDC.  The relay instructions indicate its control circuit can be powered by 3.5VDC up to 32VDC, so I'm going to try 5V and maybe 13V (Aux port can deliver 5-13VDC) and see if there are any differences.  Hopefully something crazy like that will solve the interference issues!

Relay input Amperage:  Here's an interesting note: Crydom's instructions state that the max input current is 1.6mA @5VDC or 28mA @32VDC (I'm not sure why the current is higher for higher voltage--I would expect higher voltage to require less current...anyway...).  The XW's Aux port specifications say that it can deliver 5-13VDC and up to 200 mA!  But the amperage output is not customizable on the XW.  Could it be that the Aux port is sending way too much power (amperage) to the SSR?  Or is the current (amperage) level going to be determined by whatever the SSR "needs" or "pulls", and no more?  Next time I'm in the village I can put my Amp meter on that control circuit wire and see how much current is going through it to be sure...

Ferrite beads: could you explain? Never heard of 'em.

Charge controller status:  I need to go through the display readings in the mornings of my subsequent tests and see what the XW's says its charge state is: does it say it's in float stage when I'm getting these low readings, or does it say its in bulk, but just delivering less-than-bulk output?  I forgot to check this before.  It should only be in bulk, because my batteries have always been in the 12.2-12.4 range in the mornings after having load(s) on the night before.

That's all for now. In the mean time, trying to get back to the village soon to run more tests and finish house-building!...
 

Posted by Matthew E on Oct 5, 2010 12:03 pm

#19 -  Renewable Energy > Technical Discussion: Solar Electric System - Photovoltaic > Re: Xantrex MPPT low output problems
Heh heh ahh yes, you do know 3rd-world thinking!  Thanks for the tip, but in our village, these people still don't know the difference between an electrical cable and a piece of nylon clothes line!  So the main thing I have to watch out for is somebody hacking my PV panels off of their mount with a machete, then trying to haul them downriver to sell in another village that DOES know how to use them! Smiley

Edit: just for clarification, yeah I've been observing this charging issue consistently when I'm in the village, able to monitor loads (or possible power-stealing).  When I left I had to shut off the freezer & all loads since I haven't figured out what's going on yet, and just let the charge controller float charge the batteries til I get back to the village again.
 

Posted by Matthew E on Oct 4, 2010 09:02 pm

#20 -  Renewable Energy > Technical Discussion: Solar Electric System - Photovoltaic > Re: Xantrex MPPT low output problems
Nope, the center tab is not contacting anything.  If using one side of the diode is fine, I'm back to the drawing board on this mystery. 

Next time I'm back in the village where my setup is, I'll have to try some other maintenance I've been meaning to do, and see what happens (replace corroded battery cable lugs, install an additional ground rod, take my 100Ahs out of my battery bank to test performance of the two 200Ahs alone, etc.)  But if any of those were the problem, it seems I would have this charging problem every morning, not just mornings when I've got loads going through that relay.

Take a gander (this before I added the 200Ahs):



 

Posted by Matthew E on Oct 4, 2010 07:02 am

#21 -  Renewable Energy > Technical Discussion: Solar Electric System - Photovoltaic > Re: Mixing battery sizes in one battery bank?
What do you suggest using for a bushing behind those custom bus bars when mounting them?
 

Posted by Matthew E on Oct 4, 2010 06:42 am

#22 -  Renewable Energy > Technical Discussion: Solar Electric System - Photovoltaic > Re: Xantrex MPPT low output problems
Ok, I may be on to something here.  When I wired my diode, I only wired the negative to one of the outside tabs on the diode.  Then the positive to the middle tab. 



Should I have wired the negative to BOTH of the outside tabs, like your diagram shows?  I thought the avionics friend said just use one side, but I may remember wrong...
 

Posted by Matthew E on Oct 1, 2010 03:50 am

#23 -  Renewable Energy > For Sale > Submersible hydro UW100 for sale
For sale, 12VDC submersible hydro, up to 8A or 100
W peak output.Small, propeller-driven (prop about the size of an outboard motor prop; unit only about the size of a basketball).� Tons of extra parts.� Brand new, I just tried it once in our river and realized I don't have sufficient water current for significant output. Sad�  See details where I bought it: http://www.absak.com/catalog/product_info.php/cPath/33_89_90/products_id/3�  .�  If you're interested, let's talk prices.�  I can't use it, so I hope someone can! -Matt
 

Posted by Matthew E on Oct 1, 2010 03:25 am

#24 -  Renewable Energy > Technical Discussion: Solar Electric System - Photovoltaic > Re: Xantrex MPPT low output problems
Hey Dave, thanks for the help.  I'm getting over my head, but still trying to follow you and learn in the process! My responses:

a) ok

b)could be, BUT this issue ALSO occurs when ONLY the freezer is running, and the satellite system is off.  Seems like whatever the issue is, it's common to both the freezer and satellite system (although it's possible they each have their own interference issues). Since both run through the relay and both have diodes on them, I'm thinking through whether maybe I have the wrong kind of diode?  I'm past my understanding here, so an avionics acquaintance gave me some diodes he had lying around, saying they should work.  But they may be the wrong ones. The diodes are very small black squares about the size of your finger nail, with a small metal protrusion at the top and a hole through the metal for mounting purposes.  The one on my freezer has white lettering with "LT 2420" at top, then "SBL 2040CT" or maybe it's "BBL 2040CT" (hard to see where I have it installed).  The one I've been using on my satellite system has "LT 5220" then "BBL2040CT."  Crydom's installation papers and tech tips re: DC SSRs specify certain types of diodes (e.g. "fast recovery type").  Help me out- what do I have and what do I need?  And do you agree with the Crydom instructions that "all loads should be treated as inductive even if not marked as such", and should therefore have diodes installed, e.g. DC lights?

c)(or "3") Smiley If I can figure out how to post a .bmp I'll send a diagram of how I have these diodes wired now.

d)thanks I have seen that XW bulletin and as such have not grounded the batteries elsewhere except through the XW's GFCI circuit. So that should be fine.

re: your edit: "we do need to check that the load is on the low side (negative) for those n-channel fets though?" Wow, now you've lost me.  If you can, bring it down to laymen's terms on that one. Smiley Thanks!
 

Posted by Matthew E on Sep 30, 2010 07:10 pm

#25 -  Renewable Energy > Technical Discussion: Solar Electric System - Photovoltaic > Re: Mixing battery sizes in one battery bank?
by the way, how do you post pics or diagrams in your response, Dave? I'd like to do the same. -Matt
 

Posted by Matthew E on Sep 30, 2010 07:07 pm

#26 -  Renewable Energy > Technical Discussion: Solar Electric System - Photovoltaic > Relay or diodes causing Xantrex MPPT low output problems?
I've done some narrowing-down, and found out that when I leave my inverter (Prosine, 12VDC->220VAC) on overnight, I do not have the charging problem in the morning.  But when I leave my freezer or satellite internet system on overnight (through a Crydom 40A DC relay controlled by the Xantex Aux output, each with a diode installed to guard against the transient voltage from the relay), the charging problem occurs in the morning. With no loads on overnight, there is no charging problem in the morning.  So something's going on with that relay-diode setup I think.  Any ideas?
 

Posted by Matthew E on Sep 30, 2010 07:00 pm

#27 -  Renewable Energy > Technical Discussion: Solar Electric System - Photovoltaic > Re: Mixing battery sizes in one battery bank?
Ok, thanks Michael for the advice! -Matt
 

Posted by Matthew E on Sep 30, 2010 06:59 pm

#28 -  Renewable Energy > Technical Discussion: Solar Electric System - Photovoltaic > Re: Mixing battery sizes in one battery bank?
Thanks Aaron for the advice- really helpful. -Matt
 

Posted by Matthew E on Sep 30, 2010 06:58 pm

#29 -  Renewable Energy > Technical Discussion: Solar Electric System - Photovoltaic > Re: Mixing battery sizes in one battery bank?
Thanks Dave for the ideas.  Curious- why do you have 3 red cables coming from your positive bus bar in your battery combiner pic?
 

Posted by Matthew E on Sep 30, 2010 06:31 pm

#30 -  Renewable Energy > Technical Discussion: Solar Electric System - Photovoltaic > Re: Xantrex MPPT low output problems
Hey, thanks for the tips!  I'll try those things! The batteries are all new, and haven't been totally discharged, but it's a third-world country and one always has to double-check things in case there was damage in shipment or something not immediately evident.  Appreciate the help... -Matt
 

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