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Topic: HPV 22B Solar Controller Problem (Read 21 times) previous topic - next topic
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HPV 22B Solar Controller Problem
Yahoo Message Number: 157579
This was installed in our LD back in 2007.

We are currently plugged in. The converter is a three stage PD.

We have the controller on and set to shore power. Yesterday morning in full sun I happened to glance at the controller which was set to display battery voltage. I noticed that it was rapidly and wildly fluctuatiing from the mid 13s to the mid 14s and was doing this for a minute or more. Or curse, it shouldn't read more than around 13.6 when set on shore power anyway.  I tried turning it off and then back on and after a minute it started doing it again. Numbers were changing rapidly. So, I turned it off and turned it back on later in the day and it has remained stable.

This happened once berfore and surprisingly it was at night.

We also have a See Level gauge which has a battery voltage reading. When I turned the controller off and checked the reading there it was a steady 13.2 which is what I would expect given the three stage converter.

Would this suggest that the converter is failing?

I called AM Solar today and he had no explanation and also thought it would be hard to diagnose given the intermittent nature of the problem. He thought it might be best to replace the unit. If I do I am planning on going with the Blue Sky 3000i which, of course, doesn't fit the old opening well without modification. Since the wires are already there I want to use the same space. Has anyone else had to do this and do you have any suggestions for making the conversion look good?
Re: HPV 22B Solar Controller Problem
Reply #1 –
Yahoo Message Number: 157601
I intended to ask. Does it sound like the solar controller is failing not the converter.

Also, has anyone here put a Blue Sky 3000i in the same hole they had previously had an HPV 22B.

One more question if you did make that swap can you use the same temperature compensation sensor wiring?

Jim C
Re: HPV 22B Solar Controller Problem
Reply #2 –
Yahoo Message Number: 157615
"Has anyone else had to do this and do you have any suggestions for making the conversion look good?"

The Sky Blue 3000i is taller and narrower than the HPV-22B, requiring modifications to fit correctly.
Here is how I installed one.
https://www.flickr.com/photos/lwade/albums/72157661711994929

It's a good time make sure the wiring to and from the controller are large enough to keep the voltage drop down to less than 3%, between the panels and the battery.
LD  tends to undersize the solar wiring and fusing.

Larry
Larry
2003 23.5' Front Lounge, since new.  Previously 1983 22' Front Lounge.
Tow vehicles  2020 Jeep Wrangler Rubicon, 2001 Jeep Cherokee
Photo Collection: Lazy Daze
Re: HPV 22B Solar Controller Problem
Reply #3 –
Yahoo Message Number: 157647
Hi Jim, just back from exercising my rig. Funny (not) you should post this now. I decided to check my HPV 22B, since I was going down anyway just for the heck of it. The rig is not plugged in and I have it set on Shore Power. When I looked at it upon entering, it read a whopping 19.3! With just 2 85w panels on the roof, I didn't think there was any way it could go that high. If this were accurate, I would have expected the rig to either be on fire or find melted batteries or wires. Neither was apparent. Flipping it off, then on, seems to have corrected it, but now I'm a bit worried.

Of course I'm leaving for 2 weeks (not in the rig) so I can't monitor it for now. But when I return, I'll see if it is still doing it. If so, perhaps I'll switch it out for the old on HPV 22 to see if it also exhibits this. Let us know what more you discover.

David G
2005 MB
Re: HPV 22B Solar Controller Problem
Reply #4 –
Yahoo Message Number: 157661
David, I am still working with AM Solar. In fact, have been talking with and emailing the guy there that was involved with the HPV 22B originally, although he is now retired.

He has me checking some things as he is trying to rule out whether or not the Progressive Dynamics 3 stage converter might be causing the fluctuation. Of course, in my mind, the fact that when we switched it off the reading on our other gauge stabilized at 13.2 would suggest that the converter isn't causing this, but what do I know.

Today, it started fluctuating and when I checked charging amps they too were fluctuating between 00.0 and 01.3. Now he wants me to check and see if when the amps are high the voltage is high as well or just the opposite. Apparently if they are the opposite he believes that indicates fluctuation is the converter. Of course, it quit fluctuating so will have to keep an eye on it.

In your case, my concern would be possible damage to 12v components since most are only rated for up to 16V.

Jim C
Re: HPV 22B Solar Controller Problem Now Converter Problem
Reply #5 –
Yahoo Message Number: 157704
Thought I would report an update on the solar controller issue. Turns out it isn't the solar controller but is the Progressive Dynamics PD4645 converter. From what we can tell it appears that something has gone haywire with the circuitry of the charge wizard. How that was concluded was by unplugging the wires to the charge wizard at which point the voltage fluctuations stopped and it was stable at 13.6.

At this stage I am going to run it that way and check the voltage with a meter over the next few days to see if it is still functioning as it should by changing to a float level charge of 13.2 within 30 hours. If it doesn't I will need to replace it. This was the recommendation of the person I spoke with at Progressive Dynamics. Since I don't ever manually change the setting using the charge wizard I don't really need that function as long as it is still automatically changing the charge level.

Jim C
Re: HPV 22B Solar Controller Problem Now Converter Problem
Reply #6 –
Yahoo Message Number: 158131
Final update on this issue. Replacing the converter cured the problem. Apparently the charge wizard failed in the PD4645 converter.

For anyone that might want to see what I was talking about regarding the erratic voltage reading take a look at this video.

https://www.flickr.com/photos/22123849@N02/24049749649/in/datetaken/

This is the same kind of fluctuation I was getting with the solar controller turned off and reading voltage at the battery terminals with a digital meter.

Additionally, when it came to replacement it was cheaper to go with replacement from Progressive Dynamics. If you are sending in your old unit they only charge $110 plus shipping of $16. You have 30 days to return your old unit or they charge you the full replacement price for the converter which for them was $231. This is an out of warranty deal. It was my understanding, and perhaps I misunderstood, that you are getting a refurbished unit although mine appeared to be new and included the DC board which I didn't replace.

Jim C
 
Re: HPV 22B Solar Controller Problem Now Converter Problem
Reply #7 –
Yahoo Message Number: 158133
Apparently the charge wizard failed in the PD4645 converter.

--- Thanks for this update; I also have the PD4645, so the failure of yours is not good news! I haven't noticed any problems so far with my current set up (2 AGMs, PD4645, Blue Sky 3000i), but the "heads up" is much appreciated!

Joan
2003 TK has a new home