I have the following setup with classic 150 charge controller that worked great for about 2 wks before showing some signs of potential problem.
Here is my setup:
2 string of 260amp batteries - 4 in series to produce 48v (8 batteries in total)
Classic 150 CC - serial number CL09761
Sukam 3kva inverter
6 strings of 300w panels - 2 in series with combined Vmax as 76V (12 panels in total)
This setup was commissioned on 23th December 2013 and worked without issue for 2 wks.
During daylight, CC input side show zero input and read correct battery voltage.
Decided to troubleshoot and narrow down source of issue.
1) Switch OFF Pv input to CC and measured output voltage on combiner box. Voltmeter reading gave 78V
2) Switch ON Pv input to CC, measured back output from combiner box, this time voltmeter reading dropped down to
almost zero.
3) Disconnected all wiring on CC, did continuity test on Batt+ and Batt-, no continuity sign
4) Check for continuity on Pv+ and Pv-, this gave continuity indication with voltmeter having continuous bleeping sound.
Please what could have made classic to have continuity reading on Pv+ and Pv- and what is remedy to fix it.
First wild guess is the Classic has failed and somehow shorted the input. If all cables are removed.
Did it show continuity with the leads reversed?
Some circuits might look shorted one way and it is just conducting thru a diode or transistor junction.
I poked Ryan on this. He has forgotten more on troubleshooting Classics than I ever knew. Even the best gear can fail. Ryan will help you sort it out, I am sure.
Good luck with it.
Tom
Quote from: TomW on February 10, 2014, 12:45:23 PM
First wild guess is the Classic has failed and somehow shorted the input. If all cables are removed.
Did it show continuity with the leads reversed?
Some circuits might look shorted one way and it is just conducting thru a diode or transistor junction.
I poked Ryan on this. He has forgotten more on troubleshooting Classics than I ever knew. Even the best gear can fail. Ryan will help you sort it out, I am sure.
Good luck with it.
Tom
Thanks Tom, I reversed the leads and continuity test still prove positive.
To get a few things straight:
Controller appears to boot correctly, and remains in sleep? Saying reason for rest, low light?
When PV connected to classic you measured (multimeter) the Vpv as 0V?
Classic itself (MNGP) says Vpv=0v?
You measured Voc (multimeter) of the array disconnected from classic as 70+V?
Did you measure the Isc (multimeter) of the array disconnected from the classic? With the pv breaker off, take a short peice of 10AWG/4mm2 and temporily connect it betw the pv side of the pv breaker and the negative bus. Use a clamp meter on that wire to measure the result. This will correctly rule out any array issues.
Quote from: zoneblue on February 10, 2014, 02:45:29 PM
To get a few things straight:
Controller appears to boot correctly, and remains in sleep? Saying reason for rest, low light?
When PV connected to classic you measured (multimeter) the Vpv as 0V?
Classic itself (MNGP) says Vpv=0v?
You measured Voc (multimeter) of the array disconnected from classic as 70+V?
Did you measure the Isc (multimeter) of the array disconnected from the classic? With the pv breaker off, take a short peice of 10AWG/4mm2 and temporily connect it betw the pv side of the pv breaker and the negative bus. Use a clamp meter on that wire to measure the result. This will correctly rule out any array issues.
Follow up to your suggestions:
Measured current delivery from each string of panel and I am getting around 3.5A as of 8am sunlight. Combined value from 6 strings would hover around 20A.
As mentioned earlier, seems Pv side of Classic is shunting off voltage output from array as soon as Pv breaker is turned ON. This is further confirmed by continuity reading being observed between Pv+ and Pv- of the classic.
Classic is reading correct battery voltage after booting up but stuck to zero on Pv input side.
just a couple suggestions..
Closely inspect the PV input cables to the Classic especially at the blue terminal block in the Classic. Make sure there is no short between the PV + and PV -
I saw this once when 4 guage cables were used and a few stray strands got shorted.
Also totally remove the PV cables from the Classic and with just the battery connected power on the Classic. The input show show a voltage above Zero which is normal. If it does not then the Classic may need servicing.
dgd
Please call or email mat@midnitesolar.com. I suspect you have a broken Classic and he can help you
Quote from: Halfcrazy on February 11, 2014, 06:08:46 AM
Please call or email mat@midnitesolar.com. I suspect you have a broken Classic and he can help you
Thanks a million.
Already sent a mail yesterday with some attachment to Ryan which I am yet to get any response. The mail have been forwarded to mat@midnitesolar.com as you suggested. Hopefully a response would come soon.
Quote from: Halfcrazy on February 11, 2014, 06:08:46 AM
Please call or email mat@midnitesolar.com. I suspect you have a broken Classic and he can help you
Please what is Mat phone number. Sent out a mail yesterday and no response till now.
Eventually Mat replied my mail. Classic already packaged for repair. Would update the house as events unfold. Thank you all.