Low light issue

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waynec5
Forum Member
Posts: 7
Joined: Mon Oct 11, 2021 9:19 pm
My RE system: Flexmax 60
2x Tenesol 200w, Vmp 27.1v, Imp 7.4amps
12v 190ah deep cycle Enersys slimline bty.

Low light issue

Post by waynec5 »

Hi, just installed a fm60 in my rv (caravan). I've bolted it directly to the wall which is grounded to the grid power though my system is off grid. I'm using 2x Tenesol 200w, Vmp 27.1v, Imp 7.4amps and 8mm2 wire over a distance of just under 10 m. PV module states voc 33v, I get 29/30v with a Fluke 177 (no conductors connected) and 28.5/6v with pv's connected to fm60 and breaker on. Voltage reads 28.5/6v at cc pv terminals but displays 28v/27.9v on the screen. It also displays 0.0 amps (in) and 0.1 (out) . When waking up and tracking the (in) amps flicker 0.0/0.1/0.2/0.0 and the same with out amps. Please advise
raysun
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Posts: 5909
Joined: Tue Jul 26, 2016 5:57 am
My RE system: Flexpower Two: (2) FXR3048A-01, (2) FM80, MATE3s, FlexNetDC
SimpliPhi 48-3.8 (6 @ 48v)
Outback IBR3 battery enclosure
REC Alpha 440W panels - 2 arrays: each of 4 strings of 2 in series
Honda EU7000is gas fuel generator

Re: Low light issue

Post by raysun »

The post title reads "Low light issue". How does the controller behave in full sunlight?
waynec5
Forum Member
Posts: 7
Joined: Mon Oct 11, 2021 9:19 pm
My RE system: Flexmax 60
2x Tenesol 200w, Vmp 27.1v, Imp 7.4amps
12v 190ah deep cycle Enersys slimline bty.

Re: Low light issue

Post by waynec5 »

Precisely the issue, during midday sun or any sun it displays the same thing, wake up, tracking then low light then back to snoozing. All the while l monitor the amps in and out but no change worth mentioning. I switched off the pv's breaker and put a load on the battery and also there's no change in the amps, stays at 0.0/0.1.
raysun
Forum Emperor
Posts: 5909
Joined: Tue Jul 26, 2016 5:57 am
My RE system: Flexpower Two: (2) FXR3048A-01, (2) FM80, MATE3s, FlexNetDC
SimpliPhi 48-3.8 (6 @ 48v)
Outback IBR3 battery enclosure
REC Alpha 440W panels - 2 arrays: each of 4 strings of 2 in series
Honda EU7000is gas fuel generator

Re: Low light issue

Post by raysun »

waynec5 wrote: Tue Oct 12, 2021 10:15 am Precisely the issue, during midday sun or any sun it displays the same thing, wake up, tracking then low light then back to snoozing. All the while l monitor the amps in and out but no change worth mentioning. I switched off the pv's breaker and put a load on the battery and also there's no change in the amps, stays at 0.0/0.1.
OK.

The two categories on the FM front panel: IN and OUT, are the Input (from PV) Volts and Amps, and Output (To battery) Volts and Amps. (As an aside, putting a load on the battery will not register on the FM, it only tracks what it is putting into the battery, not what the loads are taking out.)

Since this is a new installation, wiring is the first suspect.

Are the PV panels wired in series or parallel? (From the OP, I suspect parallel, possibly using "Y" combiner cables.)

Another remote possibility is a defect within the FM60. Here's a simple diagnostic: viewtopic.php?f=29&t=14942

Also, an operational tip: Never attach PV to the charge controller without attaching the battery first.
raysun
Forum Emperor
Posts: 5909
Joined: Tue Jul 26, 2016 5:57 am
My RE system: Flexpower Two: (2) FXR3048A-01, (2) FM80, MATE3s, FlexNetDC
SimpliPhi 48-3.8 (6 @ 48v)
Outback IBR3 battery enclosure
REC Alpha 440W panels - 2 arrays: each of 4 strings of 2 in series
Honda EU7000is gas fuel generator

Re: Low light issue

Post by raysun »

Another suspect on a new installation is battery voltage mis-specified during setup. Check the FM60 configuration to confirm its set for 12V.
waynec5
Forum Member
Posts: 7
Joined: Mon Oct 11, 2021 9:19 pm
My RE system: Flexmax 60
2x Tenesol 200w, Vmp 27.1v, Imp 7.4amps
12v 190ah deep cycle Enersys slimline bty.

Re: Low light issue

Post by waynec5 »

Thanks Raysun, yes pv's are parallel, I suspect internal problem, I must mention I bought the cc 2nd hand and the pv's but I suspect there's an issue with the cc. I definitely won't be going through the painful and expensive rigmarole of sending it to the appropriate experts. I have some experience in repairing inverters and power supplies so I'll be opening up this one and checking caps and mos's and everything I can. The link you sent confirms. With pv breaker off the volts decrease gradually all the way to 0. At night with the pv breaker on the in volts indicate 09v.
raysun
Forum Emperor
Posts: 5909
Joined: Tue Jul 26, 2016 5:57 am
My RE system: Flexpower Two: (2) FXR3048A-01, (2) FM80, MATE3s, FlexNetDC
SimpliPhi 48-3.8 (6 @ 48v)
Outback IBR3 battery enclosure
REC Alpha 440W panels - 2 arrays: each of 4 strings of 2 in series
Honda EU7000is gas fuel generator

Re: Low light issue

Post by raysun »

waynec5 wrote: Tue Oct 12, 2021 9:01 pm Thanks Raysun, yes pv's are parallel, I suspect internal problem, I must mention I bought the cc 2nd hand and the pv's but I suspect there's an issue with the cc. I definitely won't be going through the painful and expensive rigmarole of sending it to the appropriate experts. I have some experience in repairing inverters and power supplies so I'll be opening up this one and checking caps and mos's and everything I can. The link you sent confirms. With pv breaker off the volts decrease gradually all the way to 0. At night with the pv breaker on the in volts indicate 09v.
Sounds like a problem with the power circuitry alright.

The caps are one component to test. Also the power FETs. If you can get into the menus, check the logging for Lifetime Maximum V(oc). If its exceeded 150V by any appreciable amount, the power circuitry likely took a hit.
waynec5
Forum Member
Posts: 7
Joined: Mon Oct 11, 2021 9:19 pm
My RE system: Flexmax 60
2x Tenesol 200w, Vmp 27.1v, Imp 7.4amps
12v 190ah deep cycle Enersys slimline bty.

Re: Low light issue

Post by waynec5 »

Sure I'll check the menu now, probably will find it has exceeded the max cause I've just opened up and with a visual I can clearly see 3x mosfets fried and several driver resistors burnt. I'm going to sort out the mosfets and driver circuits and replace the caps and then see what it does and let you know. Thanks
raysun
Forum Emperor
Posts: 5909
Joined: Tue Jul 26, 2016 5:57 am
My RE system: Flexpower Two: (2) FXR3048A-01, (2) FM80, MATE3s, FlexNetDC
SimpliPhi 48-3.8 (6 @ 48v)
Outback IBR3 battery enclosure
REC Alpha 440W panels - 2 arrays: each of 4 strings of 2 in series
Honda EU7000is gas fuel generator

Re: Low light issue

Post by raysun »

waynec5 wrote: Wed Oct 13, 2021 3:16 am Sure I'll check the menu now, probably will find it has exceeded the max cause I've just opened up and with a visual I can clearly see 3x mosfets fried and several driver resistors burnt. I'm going to sort out the mosfets and driver circuits and replace the caps and then see what it does and let you know. Thanks
Though a distinction without a difference, another potential failure is too large an array for the power rating of the unit causing an over-current failure.

Good luck with your project!
waynec5
Forum Member
Posts: 7
Joined: Mon Oct 11, 2021 9:19 pm
My RE system: Flexmax 60
2x Tenesol 200w, Vmp 27.1v, Imp 7.4amps
12v 190ah deep cycle Enersys slimline bty.

Re: Low light issue

Post by waynec5 »

Hi there, I'm hoping you can assist with the values of the following resistors on fet board (mosfet drivers). They're burnt black and I'm trying to figure out their values based on the others and then I thought if I could just get hold of a clear image of the board. These are them :
R127
R128
The one between R3 and R131
R135
R136
R137
That would be a huge help otherwise I'm stuck.
raysun
Forum Emperor
Posts: 5909
Joined: Tue Jul 26, 2016 5:57 am
My RE system: Flexpower Two: (2) FXR3048A-01, (2) FM80, MATE3s, FlexNetDC
SimpliPhi 48-3.8 (6 @ 48v)
Outback IBR3 battery enclosure
REC Alpha 440W panels - 2 arrays: each of 4 strings of 2 in series
Honda EU7000is gas fuel generator

Re: Low light issue

Post by raysun »

waynec5 wrote: Thu Oct 14, 2021 9:26 am Hi there, I'm hoping you can assist with the values of the following resistors on fet board (mosfet drivers). They're burnt black and I'm trying to figure out their values based on the others and then I thought if I could just get hold of a clear image of the board. These are them :
R127
R128
The one between R3 and R131
R135
R136
R137
That would be a huge help otherwise I'm stuck.
Maybe someone with disassembly experience on FM60s can help with that. I only have FM80s and they are in production.
waynec5
Forum Member
Posts: 7
Joined: Mon Oct 11, 2021 9:19 pm
My RE system: Flexmax 60
2x Tenesol 200w, Vmp 27.1v, Imp 7.4amps
12v 190ah deep cycle Enersys slimline bty.

Re: Low light issue

Post by waynec5 »

Yes thanks
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