Converter Causing Generator Surge

[hittingtheroada]

I have a 5th wheel with a Progressive Dynamics Inteli-Power Converter. When dry camping we use a Honda 2000 generator to recharge the batteries. Lately when I start the generator in the morning and the converter goes into the boost mode of 14.4 volts the generator will start to surge even without the RPM's increasing. I have to use the remote pendant to put in in the normal mode of 13.6 volts for about an hour then it can be placed in the boost mode and it will run normal. I have 2 generators and it happens with either and also when the 2 of them are hooked together with parallel cables. This has never happen in the past. A technician at the company said it was impossible for the converter to cause this and it has to be the generator. One generator is brand new and the other almost new. I am leaning toward a new converter but before spending the money would like advise from someone knowledgeable
on the subject. Thanks.

[MrWizard]

Glad you fixed it
BTW your generator was"Hunting"
Up and down speed oscillation is called hunting

[alphamorph]

Replaced both existing 730 Deep Cycles with two new 750s from Costco and mystery is solved. Despite both 730s testing as 'good' they were apparently malfunctiioning when discharged by only a 1/4 or so. Bottom line.... problem is resolved and solution was indeed, the batteries. My thanks to all those who responded and cudos to those who pointed to the batteries as the probable issue.

[bigfootford]

alphamorph wrote:
Thankyou all. WA8 makes a good point as mine is the 80amp model BUT by 'surge', I mean the generator doesn't only rev up; it oscillates up and down in revs after an brief, initial high rev. It is becoming clear that the batteries are getting long in the tooth and when low in charge, the smart wizard on the converter is sending high and medium charges to the batteries which in turn causes the econo throttle to attempt to accommodate. I will install a couple of new batteries and after initial charge up, drain them half way down and test my theory. Will let you know findings.

So prove it with the microwave or 1300-1500 watt electric heater.

Batteries that are going bad, sulfating ,act like charged batteries, thus reduced load.

Jim

[Ezbagr]

Me thinks that this is a generator problem. I had one do that last fall and when I took carb apart there was a piece of dirt or whatever in the needle seat area that was causing generator to run as you described.

[alphamorph]

Thankyou all. WA8 makes a good point as mine is the 80amp model BUT by 'surge', I mean the generator doesn't only rev up; it oscillates up and down in revs after an brief, initial high rev. It is becoming clear that the batteries are getting long in the tooth and when low in charge, the smart wizard on the converter is sending high and medium charges to the batteries which in turn causes the econo throttle to attempt to accommodate. I will install a couple of new batteries and after initial charge up, drain them half way down and test my theory. Will let you know findings.

[wa8yxm]

Just a thought but you did not say which PDI converter you had, I mean the 9200 line runs from like 30 to around 80 amps that I know of.

A 9280, in theory, can suck around 1100 watts.. if the batteries are low and it is first engaged.. And yes, this will make a Honda EU-2000i, kick into HIGH gear (Surge) as well it should. I mean its over half the rating of the generator.

[bigfootford]

If you have a microwave you can put a coffee cup with water in it and run it with the Gen for 2 min. That is enough of a load to check the performance of the gen. Or a 1200-1500 watt electric heater!

If the gen is slowing due to the carb and it is under enough load it will not be able to handle the load and will trip out.

Simple as that.

(trip out? The overload light will turn on and the gen will return to idle if eco mode is on and remain wide open, and the only way to get it out of trip mode is to shut it off and restart)

If the gen is slowing because of load change it will slow normally and rev up as the load increases... Simple as that.

Jim

[MM49]

alphamorph wrote:
Thanks for the reply MM49. Why would this occur now (after 4 years)with the old generator and setup. I would be quick to agree if it was only happening with the new generator but both generators are reacting identically when I throw the switch and connect the batteries..... BUT, the problem seems to be overcome if the generator is allowed to run for about 15 or 20 minutes and then connected to the batteries.... so you may have something. It's just that they run so well otherwise, even under very heavy loads.

Can you correct the condition by setting the choke on slightly?
MM49

[MrWizard]

Maybe the "current" fuel being produced and used
Try a higher octane fuel, or add some Nitromethane RC fuel from the hobby store
To the gas

[KJINTF]

How about some additional data

How old is the conveter?
What is the voltage at the converter AC input / DC output?
Do either vary during the RPM change of the generator, how much?
Have you got a AC clamp on amp meter?
How much current is the Converter taking?
How about a DC clamp on meter - how much are the batteries taking at the different voltages?

Over the years repaired several PD converters most with input side caps defective. Suggest you take it out and open it up look closely at the components - normally a visual inspection quickly shows the problem area.

[alphamorph]

Thanks for the reply MM49. Why would this occur now (after 4 years)with the old generator and setup. I would be quick to agree if it was only happening with the new generator but both generators are reacting identically when I throw the switch and connect the batteries..... BUT, the problem seems to be overcome if the generator is allowed to run for about 15 or 20 minutes and then connected to the batteries.... so you may have something. It's just that they run so well otherwise, even under very heavy loads.

[MM49]

I would bet that your carb is running lean. I have adjusted the pilot fuel screw on many inverter generators. You won't believe how well it can run. They are shipped from the factory very lean for CARB emission standards.
MM49

[alphamorph]

Load tested the batteries today and both diagnosed "good". Problem persists.

[alphamorph]

All the replies suggesting a problem with gas or eco switch or anything relating to the generators aren't paying attention. I too, have two generators, one almost new and the other several years old. Both respond in exactly the same way. Startup in the morning and either generator runs high from the start, then begins to econo but instead surges gently back and forth UNTIL I throw the switch and disconnect the batteries. Without the batteries charging, either generator purrs along perfectly while running anything connected onboard but, reconnect the batteries and the same thing recurs. I have cleaned all the contact points on or near the batteries and have topped up distilled water (although they didn't need much if any). I can't wait very long for a reply as this needs to be addressed shortly. Has anyone come up with a solution?