Problem w/Xantrex SW4024

[Tenor]

I am getting an error code, telling me that my AC output and input are connected.  However, I do not have any AC output built yet!  I have been using it occasionaly this winter to top off the house batteries ONLY.  It is not wired to put out AC.  It only recieves AC.  Anyone found this problem?  I have disconnected it from the AC input, but as soon as I reconnect it, the same error signal returns.  It ran sweet this fall!  More specifically, the AC  Good indicator is on, and the error indicator is flashing. 

HELP!

Glenn

[Sean]

Glenn,

You will get this error if there is a short between either AC IN 1 or AC IN 2 and AC OUT at the junction box end of the unit.

If you have not already done so, open up the junction box and check all your connections on the terminal strip, making sure there are no stray wire strands that may be causing the short.  If you have anything at all connected to AC OUT, disconnect and insulate it, then power the unit back up to see if the problem goes away.  If so, the short is downstream in your output wiring.

If all is well in the junction box, then I am afraid one of the internal transfer relays has stuck in the closed position, meaning probably the contacts have self-welded.  That's a return-to-Xantrex kind of problem.

If your unit is already out of warranty, Xantrex has a program where you send them your bad unit, they give you a rebuilt, and you get billed later for whatever was wrong with your unit.  Most Xantrex dealers can hook you up with this deal.

HTH,

-Sean
http://ourodyssey.blogspot.com

[Tenor]

Thanks Sean,
The wiring in the box is perfect, no stray or exposed wiring.  What a pain!  I only had installed for 9 months, 6 of which have been unuseable due to winter!  Looks like I need a repair job. 

Glenn

PS,
I found a Xantrex Service Center a few hours from home.  Close enough to drive it over, since the box is gone.  Thanks again Sean!

[Sean]

I neglected to ask this, and I should have:

I presume that you have already done a complete cold-restart of the unit.  For this, removing power from the AC input alone is not sufficient -- you must also disconnect the DC input (battery connection).

This will cause the unit to start up from scratch when battery power is re-applied.  All your settings will revert to default, so make sure you write them down first, if you don't already have them someplace.

Any time you have what might be a software glitch in one of these, you should try a cold-start as part of the troubleshooting.

Also, before you go to the trouble of taking it out and driving it down there, it's worth at least a call to Xantrex technical support.  Sometimes they have some tricks you can try from the front panel that even I am not aware of.

-Sean
http://ourodyssey.blogspot.com

[Tenor]

Thats a good glimmer of hope!  I had not yet disconnected the DC supply.  I'll try that first, then call tech support.  Thanks again!

Glenn

[RTS/Daytona]

Call the Techs at Xantrex - I have a Prosine 3000

and I could not clear an error caused when I over voltaged my onan playing with the throttle

They had this somewhat SECRET reset procedure

try it - can't hurt

Pete RTS/daytona

[Tenor]

I'll call tomorrow.  I did disconnect it from the batteries for a few minutes, re-connected and recieved the same error message.  Then I moved my 110 input from AC1 to AC2 and it worked fine.  Any thoughts in the meantime would be great!  Thanks Pete!

Glenn

[Sean]

... Then I moved my 110 input from AC1 to AC2 and it worked fine. ...

Glenn,

This reinforces my belief that it is a stuck relay.  There are separate relays for AC1 and AC2, so it looks like the AC1 transfer relay is frozen closed.  Again, this can happen by "self welding" -- the relay closes under load, a small arc occurs, and the arc is just enough to "tack" the contacts together.

You can verify this theory, if you like.  Now that the input power is connected to AC2, and nothing at all is connected to either AC1 or AC OUT, take your voltmeter and check the voltage on AC OUT.  It should read 120 (or whatever the input voltage is at your place).  Now check the voltage across AC1.  If you see 120 there, too, the relay is stuck closed.

Give Xantrex a call.  I don't think this is a software issue, so I doubt they can fix it on the phone, but at least they can open a case for you and give you an estimate on repair.

-Sean
http://ourodyssey.blogspot.com

[Tenor]

Thanks Sean, I'll try that tomorrow before I call.  Better to have answers to their questions instead of having to stay on hold!

Glenn