Electrical

Thanks offgrid but I am still confused even with your answer...I have a Xantrex 817-2080 it's a freedom XC 2000 that's 2000 watts continuous power and 4000 watts surge and it's true sine wave / the charge controller is a Morning Star ProStar MPPT-40M which has capabilities of handling 12/24 volts with a rated load rating of 30a and max. battery charging current of 40a also I have a tri-metric TM2025 RV battery monitor tied into the system.

The installation was to pull the shore power from the breaker box going to the WFCO converter and run a new 120v 12/3 wiring to the Xantrex located under the bed in a new compartment I made next to the water heater.  From the Xantrex I ran new 120v 12/3 wiring to the 120v breakers in the breaker box. The Xantrex is also hooked up to the batteries with 0-2 wire.  I have 4/100 watt panels mounted on the roof 2 wired in series and then 2 pairs @ 24 volts wired to the charge controller.  In addition I have 2/100 watt portable panels wired in series that can be plugged into the system @ 24 volts.  The peak amperage output of the panels are a little over 5 amps per panel so I will never be limited out going to the charge controller.  Due to weight restrictions I have limited my batteries which are outside on the tongue of the 179 to 2 deep cycle 12v batteries, I realize that this is the weakest link in my system.

On the 12v side all panels are routed to the charge controller and there are battery leads (+/-) going from the charge controller to batteries and all the 12v power to the house electrical needs goes through the load terminals of the charge controller.  This power is through 8 gauge wire (both + and - and that's through wire not a frame ground for the -) from the charge controller to the breaker box 12v side.

As I have indicated to disable the WFCO converter I shut off the 120 breaker in the breaker box leading to the WFCO converter and I have done nothing to reverse polarity fuse/system.

The problem that I am encountering is that when the batteries are reaching the current set point for going to absorption from bulk charging @ currently 14.4 (from 14.7) volts the 12v lighting starts turning off and on (when in on switch position), the refrigerator powers up and down when in the any of the running positions, the thermostat turns off and on when in the running or off position, the radio is powering up and down on matter whether it is on or off.  The TV is unaffected as nearly as I can tell.  When the radio is powering up and down there is a cackling sound coming over both speakers.  Reviewing the charge controller over an computer connection it shows radical swings in voltage and amperage reading of about 5 points each.  We have been experiencing these symptoms and we're trying to iron this out.  Have been working with the techs at Morning Star.  What I have tried to elevate these issues are first reset the high voltage cut off from 15.4 to 15.1 which didn't correct the problem, then ran a chassis ground from the charge controller to the Xantrax then to the frame of the pod which didn't correct the problems, then ran a dedicated negative load line from the charge controller to the breaker box (rather than using a chassis frame negative) which has not resolved my problems.

What I am planning on doing now to resolve these issues first physically disconnect the WFCO converter + and -, then physically disconnect the polarity circuit.  I want to make sure that physically disconnecting the converter and polarity circuit will not do any harm to the system that I am using.

If this doesn't work I guess the only other option is to replace the charge controller because I believe the charge controller is not ramping to a lower current going from bulk to absorption and then to the float mode.

Any help would be apricated,

Jay    

Thanks offfgrid that makes sense to me and I will try eliminating the polarity circuit first and disconnecting the WFCO controller.  As far as the +12feed from the load side of the controller, I can't remember now I'll have to check that out, I am assuming the 12v buss in the breaker box???  And yes I am using the LVD on the Prostar.  I will let you know what I find.

Thanks podwerkz for another thought, the batteries are less than a year old but that doesn't mean their good and I haven't checked them....something more on my to do list but I am still thinking that it is something internal to the system that I have not accounted for.  Just have to find it.

Offgrid I did call the techs at WFCO and they told me that if the 40a polarity fuse is taken out (or blown) then non of the 12v system off the circuit board will function (like the lights or radio), thus saying that the polarity fuse is plugged into the circuit board and can't be disabled.  Well before I got digging into the breaker box I removed the polarity fuse and all the 12v system that could be easily checked worked???  So I have removed the polarity fuse and physically disconnected the WFCO converter from the breaker box wiring.  As to the wiring of the +12v coming from the charge controller it goes to a 30a breaker located behind the breaker box and is joined on the same side of the breaker with a lead going to the 12v buss in the breaker box circuit board and the other side of the 30a breaker is routed off under the floor to the other side of the trailer and I am assuming that is the hot lead for the slide out motors.

Now I am waiting to get some sunshine and try to replicate the problems.  I may have located and resolved my issues (hopefully) but still get to check out the batteries as podwerkz has suggested.

Thanks to all