Apparent problem with my Magnum Energy Inverter -- any ideas?

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Apparent problem with my Magnum Energy Inverter -- any ideas?

October 19, 2019, 12:22:39 pm

Hi folks,

We were just about to hit the road this morning, and we had an unexpected issue with our inverter (which has been working normally during our trip preparations). I've sent a note off to AM Solar tech support as they installed the system (way back in 2008). But I thought I would post a description of my symptoms, and see if anyone has any bright ideas or suggestions for me.

This issue just started today (everything was working fine yesterday). Came in and found the Magnum Energy remote monitor blank - no lights or info. [MS2012 2000W Inverter, MERC-50 Remote] Tried to reset the inverter, also no lights and button unresponsive. Fired up generator and remote lit up, but with an unknown fault (that's after the screen was flashing multiple things back and forth). Reset the inverter, and it seemed to work. Fault message went away (however, I did notice absorb charging over 14V when my batteries were 98% charged, so that did not seem right -- I thought I read all of my set-up parameters were saved in non-volatile memory). Anyways, plugged into shore power and things look to be working, but when I unplug shore power, the ME remote goes blank again, and light is not on at the inverter. So basically, I cannot get inverted power from the batteries. We were hoping to leave on our cross-country trip this morning, but need to troubleshoot and hopefully fix this issue.

Anyone have any ideas of what's going on from these symptoms? This is not a specialty of mine

I welcome any tips, suggestions, diagnoses, or trouble shooting suggestions.

And if I hear back from AM Solar with any definitive news, I'll report that back here as well.

Thanks in advance for any quick suggestions!

Steven & Carol Crisp

Re: Apparent problem with my Magnum Energy Inverter -- any ideas?

Reply #1 – October 19, 2019, 02:51:29 pm

If you have a voltmeter, I would start by seeing what charge you are getting into your inverter from the battery. Make sure any wires are securely attached. Not getting enough voltage from the battery (lose wire or rodent chewed on wires) might be causing the problem.

If the inverter is getting good voltage from the battery, likely the problem in the inverter itself.
Jane

Re: Apparent problem with my Magnum Energy Inverter -- any ideas?

Reply #2 – October 19, 2019, 06:16:43 pm

Inverter are notoriously finicky and ten years of living off grid with solar power has taught me to keep a spare on hand. Assume you have a bad inverter and replace it. That's hopefully and probably going to fix your problem. If it doesn't the "fun" begins.

Re: Apparent problem with my Magnum Energy Inverter -- any ideas?

Reply #3 – October 19, 2019, 07:57:12 pm

Quote from: Steve and Carol Crisp - October 19, 2019, 12:22:39 pm

(however, I did notice absorb charging over 14V when my batteries were 98% charged, so that did not seem right -- I thought I read all of my set-up parameters were saved in non-volatile memory). Anyways, plugged into shore power and things look to be working, but when I unplug shore power, the ME remote goes blank again, and light is not on at the inverter.

Did the ME remote show charge current, in addition to the 14+ volts? If not, that's another strong suggestion the batteries are not connected to the system. Perhaps the fuse on the batteries has blown, or a disconnect switch/relay is open.

Re: Apparent problem with my Magnum Energy Inverter -- any ideas?

Reply #4 – October 19, 2019, 10:30:05 pm

This is a long shot, but I once had a weird problem with my proSINE inverter/charger: the remote display panel was showing gibberish that varied randomly. The display was connected to the proSINE by a length of "silver satin" cable with telephone-style RJ11 connectors on each end. I finally tracked the problem down to corroded contacts on the connector at the inverter end. Cleaning the contacts eliminated the "haunted" behavior.

Given your symptoms (blank display, "screen... flashing multiple things back and forth"), cleaning the contacts at each end of that connecting cable might be worth a try.

Re: Apparent problem with my Magnum Energy Inverter -- any ideas?

Reply #5 – October 22, 2019, 04:34:52 pm

Hi all,

Thank you for the replies and suggestions. My apologies for being slow to respond.

As luck would have it, the problem turned out to be simple, and Jane's first response hit the mark -- check for 12V power getting to the batteries.

We had be driving two long days to get to the Big Foot factory in Michigan on schedule (after being delayed by this inverter issue), so I didn't get around to checking it out further until then. Sure enough, the large 200 Amp Class T fuse between the batteries and the inverter had blown (not visible, only detectable by volt meter, and confirmed with ohm readings after the fuse was removed).

Fortunately, AM Solar had included a spare, so as soon as it was replaced (after isolating the circuit, and then reconnecting), everything worked fine. Thankfully a simple solution. Harder to find new Class T fuses, but I eventually picked up a couple, just in case. In my research, I learned it might have also been the Inverter's mother board, which would have been much more difficult to have shipped to me (on the road), and to replace.

So, again, thanks to all of you that took the time to offer suggestions. Oh, and AM Solar also got back to me (not until Monday afternoon, so after the issue had been resolved, but still nice to hear from them), and they offered the same suggestion (blown fuse and/or motherboard issue).

So we are finally done with mandatory repairs and associated delays, and beginning the "follow-our-nose" portion of Thistle Dew Too's new adventure. Yeah! Sitting in Brown County State Park in Nashville, IN and taking a deep breath and offering gratitude!

Wish you all the best!

Re: Apparent problem with my Magnum Energy Inverter -- any ideas?

Reply #6 – October 23, 2019, 12:18:28 am

'the large 200 Amp Class T fuse between the batteries and the inverter had blown"

I don't want to spoil your happy ending, but it takes a 200+ amp overcurrent event (e.g., short circuit) to blow a 200 amp fuse. That's a Very Big Deal. In other words, unless that fuse was defective, something really bad must have happened to make it blow. If that were my rig, I'd be making a serious effort to find out what went wrong.

Re: Apparent problem with my Magnum Energy Inverter -- any ideas?

Reply #7 – October 23, 2019, 08:47:31 am

Quote from: Andy Baird - October 23, 2019, 12:18:28 am

I don't want to spoil your happy ending, but it takes a 200+ amp overcurrent event (e.g., short circuit) to blow a 200 amp fuse. That's a Very Big Deal. In other words, unless that fuse was defective, something really bad must have happened to make it blow. If that were my rig, I'd be making a serious effort to find out what went wrong.

Yes, that's a good point Andy, and I have been thinking about that. I have a couple of ideas, which I'll mention here for the wisdom of the crowd.

First, I had lost power to my levelers (as it turns out due to a heavily corroded circuit breaker which I had been unable to locate, but the factory found and replaced when I got there for my appt). So to retract the levelers (power was lost while they were down), I was instructed to jump between the bus-bar on one leveler and the chassis. That worked to retract them most of the way, but I have large Lifeline AGM batteries in my battery bay, so the battery connections were moved (by AM Solar) to the side. I remember a "spark" when connecting the jumper cable to the positive pole, because I think I touched the side of the compartment during that procedure. So that's one possibility. My inverter would have been on at that time. I was on shore power, so I now realize I wouldn't have noticed that issue as long as I was connected to shore power (this was at home, so I left it connected).

The other possibility noted by AM Solar is they have seen the Class T fuses blow due to a loose connection of the fuse to the fuse holder. When I removed the fuse to confirm it was blown, there wasn't enough room to get my 7/16" ratchet box wrench in there, so I had a relatively poor grip with the open end of the wrench, and yet it was quite easy to loosen. That surprised me, so that is the other possibility.

Do either of those seem like realistic explanations of the cause of the blown class T fuse? I hope so

Thanks for the follow-up Andy. Certainly want to stay safe. It's been a couple days now, with some miles on the rig, and no further issues.

Re: Apparent problem with my Magnum Energy Inverter -- any ideas?

Reply #8 – October 23, 2019, 01:24:34 pm

Quote from: Steve and Carol Crisp - October 23, 2019, 08:47:31 am

I remember a "spark" when connecting the jumper cable to the positive pole, because I think I touched the side of the compartment during that procedure.
The other possibility noted by AM Solar is they have seen the Class T fuses blow due to a loose connection of the fuse to the fuse holder.
Do either of those seem like realistic explanations of the cause of the blown class T fuse? I hope so

Accidentally shorting the battery, where you saw a spark is definitely a potential cause of the blown fuse. It must have been a good size spark.
200+amps is well into arc welding range.
I can't see how a loose fuse connection would cause a flow of amperage high enough to blow the 200-amp fuse, I can see how the loose connection might be burned but not the fuse element itself.

Larry

Re: Apparent problem with my Magnum Energy Inverter -- any ideas?

Reply #9 – October 23, 2019, 03:06:44 pm

Quote from: Larry W - October 23, 2019, 01:24:34 pm

I can't see how a loose fuse connection would cause a flow of amperage high enough to blow the 200-amp fuse, I can see how the loose connection might be burned but not the fuse element itself.

The problem with a lot of current through a loose connection is that the resultant heat generated, along with the current, can melt the fuse element. Fuse elements are designed to melt when heating caused by current flow raises the temperature enough. However, heat applied externally counts too.

Steve

Re: Apparent problem with my Magnum Energy Inverter -- any ideas?

Reply #10 – October 23, 2019, 07:31:21 pm

Quote from: Steve - October 23, 2019, 03:06:44 pm

The problem with a lot of current through a loose connection is that the resultant heat generated, along with the current, can melt the fuse element. Fuse elements are designed to melt when heating caused by current flow raises the temperature enough. However, heat applied externally counts too.

The OP stated
"Sure enough, the large 200 Amp Class T fuse between the batteries and the inverter had blown (not visible, only detectable by volt meter, and confirmed with ohm readings after the fuse was removed)."

A bad fuse contact, one that got hot enough to melt the a T-class fuse element, should show indications of overheating and arcing.
https://www.automationdirect.com/adc/shopping/catalog/circuit_protection_-z-_fuses_-z-_disconnects/fuses_-a-_fuse_holders/current_limiting_class_t/class_t_(300v,_1_-_200_amp)/tjn200?gclid=EAIaIQobChMIvI2qosSz5QIVkMJkCh1F4AysEAYYASABEgK61vD_BwE

I suspect something else caused it

Larry

Re: Apparent problem with my Magnum Energy Inverter -- any ideas?

Reply #11 – October 24, 2019, 08:36:00 am

Hi Larry (and Steve),

Thanks for your inputs. The "spark" I mentioned was certainly not that large, and at the time, I thought nothing of it.

Also, the fuse holder looks pristine, so there are no signs of arcing or excessive heat.

So it sounds like neither of those theories are likely the cause of the Class T fuse being blown.

Well, now I am stumped. I'll certainly keep monitoring the system, and keep an eye out for anything that seems out of the ordinary.

Thanks again for weighing in. Your experiences are certainly valued.

Re: Apparent problem with my Magnum Energy Inverter -- any ideas?

Reply #12 – November 29, 2019, 01:19:15 am

Hi All,

Just a quick closing comment for this thread. We completed our cross-country trip without any issues related to the inverter (or levelers, for that matter). So far ... so good!

If anyone is curious about where we went and what we saw, you are welcome to check out our blog (highlighted part of our signature link) and associated Flickr albums (and from there click Older Posts - this will be reverse order). Picture taking started in more earnest as we finally decompressed from the sale of our house, and found ourselves in warmer or more scenic locations.

Or you can go to the first post of the 2019 Adventure and click on Newer Posts to move through in chronological order: Thistle Dew Too: And now for the Thistle Dew Too (TD2) 2019 Adventure ......

Last option - you can skip all the banter and just go to my Flickr album page and look at the pictures: Steven Crisp’s albums | Flickr

Thanks again to the group for all of your inputs and wisdom!

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October 19, 2019, 12:22:39 pm

Reply #1 – October 19, 2019, 02:51:29 pm

Reply #2 – October 19, 2019, 06:16:43 pm

Reply #3 – October 19, 2019, 07:57:12 pm

Reply #4 – October 19, 2019, 10:30:05 pm

Reply #5 – October 22, 2019, 04:34:52 pm

Reply #6 – October 23, 2019, 12:18:28 am

Reply #7 – October 23, 2019, 08:47:31 am

Reply #8 – October 23, 2019, 01:24:34 pm

Reply #9 – October 23, 2019, 03:06:44 pm

Reply #10 – October 23, 2019, 07:31:21 pm

Reply #11 – October 24, 2019, 08:36:00 am

Reply #12 – November 29, 2019, 01:19:15 am

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