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6000xp bug in charge controller setpoint voltages with open loop

 
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Last Post by ouijifour 5 hours ago
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Posts: 31
 dtbaker61
Topic starter
October 17, 2024 9:42 pm
(@dtbaker61)
Eminent Member
Joined: 3 months ago

I'm thrilled to see a forum for EG4 that can be used as a searchable knowledge base to report bugs and get help. The first topic I'd like to see resolved is an issue I told EG4 about more than a month ago, and have yet to get resolved.

 

The issue is that if you are using the eg4-6000xp with (any) LFP batteries in 'open loop' communication; it is NOT possible to obtain a proper charge curve with user defined voltage setpoints. For example, documentation indicates that the desired charge curve can be obtained by:

batt type = 'lead acid'

bulk=eq= 56.2v, eq time = 0, eq days=0

float=54.0v

.... what this *should* result in is charging to 56.2 once per day, not spend any time at 56v, and 'relax' to float at 54 for the remainder of the day... resetting overnight when pv voltage drops to 0 for the next day.

...what happens is that the charge voltage rises to setpoint 56.2, but then 'floats' there for the remainder of the day, ignoring the desired float of 54.0.

This is not good for the batteries, and not doing what I expected or want. Its a BUG that needs to be fixed. I am posting this as a 'bug report' so that we can all be made aware when there is a firmware patch available to correct this problem.

240824 daytime floating at 56v

 

Topic Tags
charge control bug
24 Replies
Jarrett
Posts: 28
 Jarrett
Admin
October 21, 2024 2:03 pm
(@jarrett)
Technical Solutions Manager
Joined: 3 months ago

Thank you for the input! I reported this bug a while back, probably spoke with you about it. I am waiting for a resolution on this at the moment, but will message the software team about this to see what the progress on this is.

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3 Replies
 dtbaker61
(@dtbaker61)
Joined: 3 months ago

Eminent Member
Posts: 31
October 21, 2024 2:07 pm
Reply toJarrettJarrett

@jarrett , yes we had emailed back and forth several times.... This new forum will be a decent way to track open bugs, and let people know when patch fixes are available....

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 dtbaker61
(@dtbaker61)
Joined: 3 months ago

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Posts: 31
November 27, 2024 4:29 pm
Reply toJarrettJarrett

@jarrett , it's been more than a month now.... and no work back from EG4 on a firmware patch to address this bug in charge curve ?! I am not impressed. The bug still exists in ccaa-190D0E, and current charge management by Voltage is NOT following programmed Voltage setpoints..... Holding battery voltage too high for too long will negatively affect LFP battery life, and I'm not happy about that.

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Jarrett
 Jarrett
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(@jarrett)
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Posts: 28
November 27, 2024 4:45 pm
Reply todtbaker61
Jarrett

@dtbaker61 I have passed all of the information along, and I am waiting for this as well. I know that they were working on everything plus the things that they were addressing with the newest firmware patch to begin with. Testing and adjusting how everything works takes some time. Plus, we have to make sure that it doesn't just work once and works every time it is asked to float charge. I assure you we are working on it, but there are other things that we are working on as well and getting everything to function properly before roll-out is necessary so that we aren't putting out a firmware update and then another one 2 weeks later.

 

I will ask the team to hurry it up though.

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Jarrett
Posts: 28
 Jarrett
Admin
October 21, 2024 2:09 pm
(@jarrett)
Technical Solutions Manager
Joined: 3 months ago

I agree! As soon as I have some additional information about this particular issue, status update, progress reports, etc.. I will respond here again.

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 dtbaker61
(@dtbaker61)
Joined: 3 months ago

Eminent Member
Posts: 31
October 26, 2024 8:48 pm
Reply toJarrettJarrett

@jarrett .... kinda expecting an update by now. It's pretty serious to not be able to set correct bulk/float voltages. I would hope that the 6000xp charge controller would actually DO what is programmed. I.e. bulk charge to 56.2, and then float at 54.0 for remainder of the day.

 

Also, this topic should NOT show as 'solved' until there is a firmware patch released that actually fixes it, along with HOW to obtain and install the patch.

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Posts: 31
 dtbaker61
Topic starter
October 31, 2024 5:58 pm
(@dtbaker61)
Eminent Member
Joined: 3 months ago

Still, no response or followup ? very disappointed in EG4 at this point. I'm going to have to evaluate other inverters, or add external charge controllers I can trust to a product that is supposed to be 'all-in-one'. ;(

The 6000xp hardware seems to be pretty good, but the charge controller firmware stinks. We really need to be able to set parameters for a LFP-friendly charge curve.

@jarrett , PLEASE put me in touch with some senior tech and/or whomever is responsible for the charge controller firmware!

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 Dan_in_AK
(@dan_in_ak)
Joined: 3 months ago

Active Member
Posts: 8
October 31, 2024 7:09 pm
Reply todtbaker61

@dtbaker61 I have a separate but closely related post.  I have no PV hooked up (in Northen Alaska I won't get much solar gain until March), so using a generator with FLA batteries.  I have similar issues with set points not being followed, no reasonable FLA charging profile/scheme, and to make matters worse, it leaves my generator cycling between no charge and bulk charge, rather than shutting off unless I set the Gen Stop setting well below whatever the charge point is, after it's been chaging a while..

Agreed the hardware execution is decent if not good, but the programmable aspect is severely lacking.  I bought another inverter this week to solve my charging problems, although if/when I go from lead acid to lithium batteries the EG4 may be great.  Until then, I'm out another $2k to make things work right.

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Jarrett
Posts: 28
 Jarrett
Admin
October 31, 2024 6:01 pm
(@jarrett)
Technical Solutions Manager
Joined: 3 months ago

I apologize, but we still do not have a fix at this moment. Bug reports have been submitted, software engineers are aware, but they are still testing everything and making sure that it works as intended.

Unfortunately, I can't put you in touch with this person as they are not customer facing and are typically testing and writing firmware, but I have sent all of the information that you have provided directly to our R&D team so that they can get a fix implemented.

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 dtbaker61
(@dtbaker61)
Joined: 3 months ago

Eminent Member
Posts: 31
November 1, 2024 4:29 pm
Reply toJarrettJarrett

@jarrett , I'd be happy to be a beta-site tester at one of my client sites if there is a patch available that can be installed with the remote update wi-fi maintenance feature. If it works, then I'll need a patch and instructions on how to install the patch at a few of my off-grid sites that do not have cell or wifi.

I hope this issue has been escalated to 'critical', and we get weekly updates from now on... if not, I will have to consider installing external MPPT charge controllers capable of correct charge curves for LFP, and discontinue using EG4-6000xp for new installs until this gets resolved.

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Jarrett
 Jarrett
Admin
(@jarrett)
Joined: 3 months ago

Technical Solutions Manager
Posts: 28
November 4, 2024 4:23 pm
Reply todtbaker61
Jarrett

Posted by: @dtbaker61
↑

@jarrett , I'd be happy to be a beta-site tester at one of my client sites if there is a patch available that can be installed with the remote update wi-fi maintenance feature. If it works, then I'll need a patch and instructions on how to install the patch at a few of my off-grid sites that do not have cell or wifi.

I hope this issue has been escalated to 'critical', and we get weekly updates from now on... if not, I will have to consider installing external MPPT charge controllers capable of correct charge curves for LFP, and discontinue using EG4-6000xp for new installs until this gets resolved.

 

Let me pass that along to my director, and see if that is something we can do.

 

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 dtbaker61
(@dtbaker61)
Joined: 3 months ago

Eminent Member
Posts: 31
November 4, 2024 5:09 pm
Reply toJarrettJarrett
Jarrett

@jarrett , great, I'd appreciate that. What I am looking for is the ability to set inverter charge setpoints such that I get a proper CC/CV charge curve for generic LFP with open loop comms. For solar (as opposed to EVs) this *should* result in a daily charge curve that :

phase1: CC charge at max current to a Vfloat voltage (range being 52.8-54.5)

phase2: CV charge to 'end-of charge' voltage, label it bulk, or absorb, or equalize.... (range 56.0-58.4 for 16-cell LFP). This phase is beneficial to enable the internal BMS to top-balance cells within the battery as the current drops when voltage approaches the end-of-cha rge setpoint. Most importantly, the charge controller should NOT hold the battery at this voltage for any length of time once the charge current has dropped to .02C... at this point the charge is "done", and in a solar battery the goal is to end the day with batteries still at 100%, so there SHOULD be a "float" voltage setpoint or range to maintain LFP batteries in a solar installation in at, or near "full" as long as PV input is available.

phase3 (for solar): CV or CV range typically cycling between 95%-100% in off-grid situation where capacity needs to be maximized (3.35vpc and 3.37vpc, or 53.6-54.0 for a 48v nominal LFP pack). It is important to note that the charge curve should "reset" overnight (when PV voltage drops below operational level for more than some period of time greater than an hour). for a hybrid grid-tied install where grid power is available, a user may want to set this range a little lower, like 90%-95% .

 

....the existing firmware settings *should* almost do this in lead-acid-mode if the system actual did what was entered:

Veq=56.0, days=1, duration=0

Vcharge=54.0

Vfloat=53.5

 

this *should* result in a reasonable LFP CC/CV charge curve. CC to Vcharge, CV to Veq on a daily basis, with 0 duration at Veq, and floating between Vfloat-Vcharge for the remainder of the day.

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