Xantrex Inverter Not Charging Battery

[Boilermaker Chemist]

I am posting this in case anyone else has the same issue. Recently I noticed that my Xantrex Freedom XC Pro 2000 was not charging my batteries when hooked up to shore power. However, the microwave was working so the inverter portion of the Xantrex was working properly. The EMS showed good shore power voltage, 60 Hz and no errors. No errors were shown on the Xantrex external display. However, I learned on this forum that there is an app for the Xantrex (FXC Control). Upon downloading and launching the app I saw the following alert: “Utility Power Not Available/Qualified”. This indicated that there was a problem somewhere with input power.

I removed the small cover at the back of the inverter. The input and output AC connections are made by WAGO lever connectors. There is a small hole in each lever to allow the voltage to be checked with probes and a multimeter. I measured 120 V at the output of the inverter but no voltage at the input. It turns out that there was a bad connection at the WAGO connector, perhaps caused by road vibration.

After disconnecting shore power and upon removal I found that the stranded AC input wires were rather mashed together rather than twisted together. I cut those ends off, removed 10 mm of insulation as specified in the install instructions and used electrician’s pliers to gently twist the wires together. (Note:  the install instructions also specify that the exposed copper wire should be tinned with lead-free solder).  I found the reinstall to be very difficult because the levers are spring loaded and will not stay open so each wire had to be inserted in sequence. The short length and heavy gage of the wire combined with having to hold the lever open with one hand made this a very difficult task. Nevertheless, I was finally able to insert them properly using a pair of needle nose pliers. This resolved my problem and everything is working properly again.

I will also note that the app makes it much easier to check or change the settings on the Xantrex unit compared to doing so on the external display. I highly recommend it.

Edited September 13 by Boilermaker Chemist

[jd1923]

3 hours ago, Boilermaker Chemist said:

After disconnecting shore power and upon removal I found that the stranded AC input wires were rather mashed together rather than twisted together.

Wow, never seen such a thing and your Oliver is only 1 year old! I'm assuming your inverter was charging previously.

Could something have been pulling on the 10/3 cable from outside the inverter? Anything loose or stored in that basement area? 

[Boilermaker Chemist]

I don't think so.  But the locknut on the romex connector was loose so I speculate that may have allowed some movement as we traveled on the bumpy interstate highways.

[jd1923]

1 hour ago, Boilermaker Chemist said:

I don't think so.  But the locknut on the romex connector was loose so I speculate that may have allowed some movement as we traveled on the bumpy interstate highways.

That’s all it needed. Bad Q on installation!

[ScubaRx]

14 hours ago, Boilermaker Chemist said:

After disconnecting shore power and upon removal I found that the stranded AC input wires were rather mashed together rather than twisted together. I cut those ends off, removed 10 mm of insulation as specified in the install instructions and used electrician’s pliers to gently twist the wires together. (Note:  the install instructions also specify that the exposed copper wire should be tinned with lead-free solder).  I found the reinstall to be very difficult because the levers are spring loaded and will not stay open so each wire had to be inserted in sequence. The short length and heavy gage of the wire combined with having to hold the lever open with one hand made this a very difficult task. Nevertheless, I was finally able to insert them properly using a pair of needle nose pliers. This resolved my problem and everything is working properly again.

I will also note that the app makes it much easier to check or change the settings on the Xantrex unit compared to doing so on the external display. I highly recommend it.

 

I really like the WAGO style connectors. They are so expensive that I buy a generic version off Amazon. I have never had one to fail. Examining your photo and reading your post, it is my opinion that there was an installation problem. The connectors in the photo are not WAGO brand. I too had problems when I first started using them. It appears that the installer did not know that you have to pull the levers up to 90 degrees for them to stay open. He or she appears to have not known this and just slightly opened them and crammed the stranded wire into the receiver holes. Their crumpled strands indicate to me that they were never properly connected. Tinning the ends of the wires is absolutely best practice with stranded wire, solid wire doesn't really need that done. Soldering above an open circuit board is probably not the best idea though. This is a product I use when soldering is too difficult or I'm too lazy to drag out my soldering equipment.

[Steph and Dud B]

Looks like sloppy work at the factory. Also, hard to tell from the photo, but is that copper stranded wire or aluminum? It looks silver in the photo.

[Boilermaker Chemist]

12 hours ago, ScubaRx said:

I really like the WAGO style connectors. They are so expensive that I buy a generic version off Amazon. I have never had one to fail. Examining your photo and reading your post, it is my opinion that there was an installation problem. The connectors in the photo are not WAGO brand. I too had problems when I first started using them. It appears that the installer did not know that you have to pull the levers up to 90 degrees for them to stay open. He or she appears to have not known this and just slightly opened them and crammed the stranded wire into the receiver holes. Their crumpled strands indicate to me that they were never properly connected. Tinning the ends of the wires is absolutely best practice with stranded wire, solid wire doesn't really need that done. Soldering above an open circuit board is probably not the best idea though. This is a product I use when soldering is too difficult or I'm too lazy to drag out my soldering equipment.

Well,  it says WAGO on the side of the connectors.  Here's what Xantrex tech support says: "As for the levers, you may be able to get one or 2 to stay open, but usually they do not, and they have a strong spring.  It is normal." 

Thanks for the tip on the ferrules, I was thinking about something like that but wasn't sure what to use.

[Boilermaker Chemist]

3 hours ago, Steph and Dud B said:

Looks like sloppy work at the factory. Also, hard to tell from the photo, but is that copper stranded wire or aluminum? It looks silver in the photo.

I would assume that it is Marine Grade Tinned Copper UL1426.

[Steph and Dud B]

2 hours ago, Boilermaker Chemist said:

I would assume that it is Marine Grade Tinned Copper UL1426

Good point. That would be appropriate.

[ScubaRx]

On 9/14/2024 at 1:08 PM, Boilermaker Chemist said:

Well,  it says WAGO on the side of the connectors.  Here's what Xantrex tech support says: "As for the levers, you may be able to get one or 2 to stay open, but usually they do not, and they have a strong spring.  It is normal." 

Thanks for the tip on the ferrules, I was thinking about something like that but wasn't sure what to use.

I stand corrected then. All the brand name WAGO connectors I've ever seen had it printed on the levers. They DO have a strong spring. You don't want your thumbnail under it when it unexpectedly comes down.