Battery bank wiring modification

 

The battery bank has been wired in parallel with system connections at the closest battery. This creates an unbalanced load on the bank. 

The modification: instead of direct wiring to the closest battery, one connection to the closest battery (+) and one connection to the most distant battery (-).

The ideal arrangement would be separate connections to the system for each battery, a radial configuration.

Inverter final test

 

I finished the installation of the replacement lever actuated terminal connector WAGO 2606-1103.

This afternoon, I had occasion to run the inverter/generator. I plugged the unit in while the Xantrex inverter was on. The system was maintained. Notably, the RPPi4 experienced no discontinuities in the data stream.

I count this as a success.

There was a brief  lapse in the lightiing, about 1/3 second, but this was partly due to a setting on the iniverter. The transfer is set up for APL, appliances, but could be set up for sensitive electronics. The second option warns against transfers with inductive loads such as electric motors (water pump, fridge) running.

Power limit discovered

 

I have discovered the reason why my charts never rise above 560W in delivered power in my 1kw system.

My system has 24v panel system and 12v battery system. The charge controller can handle both but the inverter only takes a 12v input.

If I want to get the full 1 kw power delivery, I need to replace the 12v inverter with a 24v inverter. Then the charge controller can run at maximum capabilty. I will be able to charge the 5kw battery bank in 5 hours on a sunny day. Since the bank is never drained completely, the time will be significantly less.

'AC In' connector replacement.

I have received the WAGO 221-412 and 221-2401 connectors in the mail. Those have replaced the wire nuts traditionally used to tie two household grade wires together, typically 12/2.

I have removed the connector sub-pcb and unsoldered and removed the damaged connector using the solder iron, solder, solder sucker and flux paste.The pcb is ready for the new WAGO 2606-1103 connector. I added two push-fin cable strain relief clamps for the AC connections.

I received the new connector a couple of days ago. Preparations included setting up the new soldering iron plus solder, sucker and flux paste. The replacement went smoothly. After the replacement, I re-assembled the unit and removed the 1200W unit. I attached the 2000W unit to the wall after attaching the AC and DC cables.

I started the unit this morning and all is well. 

The final test will be the attachment of a running inverter/generator like the Predator 2000 to test shore power detection and switching.

WAGO 2606-1103 pcb connector for 'AC In'

Before

After

Repaired unit

Wire nut replacements, 'AC In'

Wire nut replacements, 'AC Out'

Inverter modification strategy.

 

The closest visual equivalent to the Xantrex unit's AC In connector is the WAGO 2606-1103.

After removing the connector pcb, I discovered the brand and general model series : WAGO 2606.

The inverter needs a modification.

An AI agent (Google) suggests adding stranded 12AWG as a stress relief strategy.

Stranded 'pigtails' go to the pcb then to WAGO splice connectors that tie stranded and solid wires together.

The existing lever connectors would be removed and stranded wire soldered directly to the pcb. Alternatively, the broken WAGO connector could be replaced and stranded wire inserted there.

The AI response mentioned an inherent weakness in using solid 12AWG wire in those connectors and that reports of loose or intermittent contact had occurred. Hence the stranded wire substitution. This is intuitively correct and appeals to experiential common sense.

Inverter modifications.

 

I tried plugging the generator into the external outlet but the inverter had an unusual display.

On re-reading the Xantrex manual, I discovered the generator has to be connected to the 'AC In' terminal.

Two problems exist.

1.) There has to be a circuit wired for the inverter, from the back porch outlet, to the inverter.

2.) One of the 'AC In' terminal blocks is bad.

I discovered the connector is a WAGO device.

That block (VAC Line) has to be replaced or the wire soldered in place after removing the bad terminal block.