whiz bang jr stuck at 100%

[russ_drinkwater]

Hi.
The reading on the wbj on my sons classic 150 appears to be "stuck" at 100%.
Any ideas why the soc is not changing?
It goes through bulk and absorb and gets to float.
I did a hydrometer reading on his L16 trojans and they were sitting on 1265 sg.
They have 2200 watts of array at the moment and peak output is between 50-60 amps.
The classic indicates it is producing 4.5 - 7.5 kw a day depending on their usage.
As days are getting colder the power usage is reducing.
The trojans are 24 volt bank and 870 amp hours.
It is setup the same as mine here, but the two show increases and decreases in the soc during the day and night.
Soc in the morning on Doug's shows 100% which should be approx 80 -85%.
Any ideas?
The purple cable has a 2ft extension to it, but so do both of mine.

[Westbranch]

BTS installed?
Working?
Temp comp set to? Reference Temp? working?
Range of ambient temps over the day and Night?
Batt temps? steady? HI? Low?
Brand / model of batts?
Manufact. Charge specs ?  settings used?

[Resthome]

Hi.
The reading on the wbj on my sons classic 150 appears to be "stuck" at 100%.
Any ideas why the soc is not changing?
It goes through bulk and absorb and gets to float.
I did a hydrometer reading on his L16 trojans and they were sitting on 1265 sg.
They have 2200 watts of array at the moment and peak output is between 50-60 amps.
The classic indicates it is producing 4.5 - 7.5 kw a day depending on their usage.
As days are getting colder the power usage is reducing.
The trojans are 24 volt bank and 870 amp hours.
It is setup the same as mine here, but the two show increases and decreases in the soc during the day and night.
Soc in the morning on Doug's shows 100% which should be approx 80 -85%.
Any ideas?
The purple cable has a 2ft extension to it, but so do both of mine.

Russ

Didn't you have an issue with the WBJr before??  Don't remember ever seeing a conclusion to it.

I'd first look at the led on the WBjr is is slowly flashing?? 

[russ_drinkwater]

The wbj is slow flashing as normal.
Yeah I had two die in different systems and ryan offered to replace them after sending photos. As it was quicker I bought 2 new ones locally.
Had no further problems with the ones on my two systems here.
They both percentage up and down in regard to SOC.
I have not been back over to sons place. Sg is 1275 after sunset and classic indicates 4.8kw on the screen, so they are getting about the right charge for the amount of usage. Goes to float every day after lunch.
L16 trojans (8 x) and all charge specs are set to trojans recommendations.
Temps range from 20-28 deg C these days outside.
Inside where the cells are sits on around 23 deg.
BTs is hooked up, will have a look today when I go over there.

[Resthome]

The wbj is slow flashing as normal.
Yeah I had two die in different systems and ryan offered to replace them after sending photos. As it was quicker I bought 2 new ones locally.
Had no further problems with the ones on my two systems here.
They both percentage up and down in regard to SOC.
I have not been back over to sons place. Sg is 1275 after sunset and classic indicates 4.8kw on the screen, so they are getting about the right charge for the amount of usage. Goes to float every day after lunch.
L16 trojans (8 x) and all charge specs are set to trojans recommendations.
Temps range from 20-28 deg C these days outside.
Inside where the cells are sits on around 23 deg.
BTs is hooked up, will have a look today when I go over there.

Is it showing a negative Net AH reading early in the morning? Assume the Battery Capacity AH setting is correct and check the other WBjr setting.

[dgd]

Some suggestions...
The WBjr is connected the correct way around on the shunt? If not then discharging will be seen as charging current and the SOC will stick at 100% with  fully charged batteries when charging is complete. Since float voltage resets SOC to 100% it will stay there until next morning when charging will be seen as discharging and SOC will reduce until FLoat resets it to 100%
The signal wire into AUX2 can be a problem. If you have extended it then it needs to be properly soldered connection. Multicore cable too as a crack/split in a single core means problems.
Make sure that little grub bolt in the AUX2 connector is properly tight.
Also ensure its not accidentally placed in AUX1 or in one of the -ve connectors.

dgd

[russ_drinkwater]

I have soldered the extension to the wire and covered it.
The aux2 screw is tight.
Not in aux1!
I will check it again in the am as it is 5pm atm here.
Battery amp hours are correct.
WBJ is correct in connection to shunt.
Just rang son and is 25.3 volts and showing 100% and has taken 7kw in today.
And the classic did hit float today.
I checked the battery temp this morning at 9am and it was 24.2 deg C.

[dgd]

Ok, have a look at the SOC when the Classic is in BULKMPPT charging mode. Is it still on 100% or at a lower value and is it increasing or decreasing?
Is there any data coming from the WBjr? can you see the remote temperature as its a temp sensor on the WBjr. Is it a valid reading?
Also are the two bolts holding the WBjr to the shunt nice and tight so that there is no movement of the WBjr on the shunt

dgd

[boB]

Interesting....  But annoying I'm sure...

At night, have him look at the A-H remaining and see if it changes at ALL.

A-H Remaining is what is used to calculate SOC%.

boB

[russ_drinkwater]

Stays at 100% overnight.
Stainless screws are very snug.
Put in 7.4 kw of charge yesterday according to the boy.
I am going to have a look at the bulk and float today if I get a chance.
Strange one of my units have a brain flip yesterday and went to float after only 1.1 kw of intake!
And the other one did 6.4 for the day.
Are they female?

[dgd]

you have checked that the Classic has AUX2 set up for WBjr and that it is not turned off?
If you are sure everything else checks out then try removing the WBjr from the shunt and reconnecting it reversed.
How much KWh power input there is probably has nothing to do with this problem.

dgd

[boB]

Does the remaining amp-hours change during the night ?

??

[russ_drinkwater]

Stays at 100% over night.
Found the problem with mine!
Battery to regulator switch was fried on one bank.
Replaced it yesterday afternoon, but I really need to upgrade those isolators switches as the amps are too high.
Both my regs are now in bulk at 6.45 am, but only 6 amps each coming in at the moment.
If I reverse the shunt it reads negative, but will shows a fluctuation in % as it should!
I am confused, lol.

[dgd]

Sorry Russ but your reply only makes this issue more confusing.
So you have this identical SOC not moving issue with more than one system since you say you have resolved mine
Also what does this mean Battery to regulator switch was fried on one bank
Are you using  ganged breakers between your battery bank and Classic,if so why? there are proper single pole Carling breakers easily available for this task.
or are you referring to another device? regulator?
How any of this could possibly cause the Classic to keep operating (charging) nomally yet cause the WBjr to not work has me confused, doesn't seem logical.
Please correct me if I am wrong.

You say when you reverse the shunt it reads negative. What reads negative?

dgd

[russ_drinkwater]

Sons system.
The readout from the whiz bang shows a negative figure. (- 15.3 amps)
But it also will allow the soc to fluctuate while connected in reverse (yes it confuses me as well)
My mate offgridqld was here at easter and even he could not come up with a cure! 
There is a toggle 200 amp breaker switch between the 150 and the battery bank.
It is weird and sg in cells is great and classic charges fine it is just that soc readout from the wbj.
Sons system is same config as mine with the exception of the batteries. And a wind turbine.
This problem continues.

My system.
My strange SOC readings and jumping to float on one bank was caused by a (fried, cooked, overheated, buggered, knackered )
breaker switch between one classic and its bank of batteries. I have replaced it and am looking for some heavier duty breakers atm.
Sorry if I am confusing!
My problem is resolved.