DougO
Model: RG025ANAX
SN: 3004196589
Fuel: LPV
Transfer switch: 200 Service rated
Firmware: current version

As the title says false " Charger missing AC " error.

Time installed about one month
Have been dealing with this issue since installed. Unit was installed by us as per install guide lines. Have been working with tech support since finding issue at startup. Have went through all of the wiring ( customer side ) that we installed ( install crew ), have changed the controller twice now at direction of support.
Things I know for sure:
Has good frame ground back to transfer switch, frame ground bonded to main earth ground at house/utility entrance.
Has good neutral back to transfer switch.
Battery charge circuit fed from breaker in sub-panel in garage fed from house where unit is located.
Voltage has been verified at 120 VAC charger connector on back of controller, battery stays charged. 118 VAC measured
This unit runs great other than this false error.

So I was just wanting to see if any of the other techs on here had ever run into anything similar to this. 

I don't have much hair left after this as it is really straining the brain cells, out of the all of the generators we have installed both air-cooled and Protector series this is a new one.


Any thoughts or questions ?

Thanks Doug
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Peddler
Does it come up all the time or just when you are having an outage or simulate one?
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ohmslaw
Did you connect a neutral at the T1 block?
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ohmslaw
If you remove the battery negative does the display shut off?
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DougO
Peddler, not sure about during a power outage real or simulated. But it is off during non-loaded running, if power is cycled it is off until the five min delay expires.

Ohmslaw, yes there is a neutral connected at the block with other end at neutral buss in sub-panel. Not about with negative cable but it does not with fuse pulled. 

Thanks for the feedback
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78buckshot
The last Protector I had trouble with was a similar issue, I can't remember the fault code or what it said but Tech Support had me page through all of the set-up parameters and we found one that a non-factory setting. He also had me change each parameter up or down one setting and then back to the factory spec., have not had any trouble since.
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Peddler
Do you have a DC amp probe to see how many amps the charger is putting out?  Are you certain the connections at the blocks are where they are supposed to be?  I have seen the decals misaligned, check the wire numbers on the factory connection side to make sure they match what you have on the field wired side.
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Peddler
So are you saying you only get the fault when it is running in manual?  Please explain " if power is cycled it is off until the five min delay expires".
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DougO
78Buckshot thank you that bit of information and i will check DC amps.

Peddler, no the error is only on when it is not running. If running in manual the error msg is not displayed.  I know i read somewhere in my manual that there is a 5 min delay before the " no ac to charger " error is diplayed if the 120vac is cycled off then backon. Or maybe i was dreaming or something.
Thank you for information as well i will be back out there on Monday hopefully.
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Peddler
I have a unit that is being used as prime power at a remote site.  It only shows the charger missing Ac when it is in the off mode.  Of course on water cooled units the  battery is being fed from the engine driven alternator.  In the case of mine the battery charger circuit is not even wired.  That is why I wonder if the battery charger is getting the AC in actuality.  If you are going out there take a picture of your battery charger connection at the block and post it.
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BrentB
Every time there is a power failure, the charger is in fact "missing AC" until the generator starts and transfers. T1 is connected to the load side of the transfer switch. For the amount of time it takes for the generator to startup, run, and transfer, there is in fact an ac power loss to the charger input which is not a false reading!
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MacL
No, I have never seen a "false" charger missing ac error.  Even with long delay times, the controller seems to hold off on the alarm until about 15 seconds after the delay time expires (15 seconds after cranking, whenever that may be).

Things to check:

The factory side of the wago block, for unstripped wire on hot or neutral;
Both sides of the plug-in connector behind the controller for backed out terminals;
Check continuity between the wago neutral and the main neutral lug in the genset;
There can also be poor terminal contact inside of a bulk-head connector, which may require a schematic and some back-probing.


Don't assume the error is false.  It is easily verified by taking off a battery cable off and seeing if the controller blanks out.
State your problem, not your diagnosis.
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DougO
Just wanted give a update since this issue has been resolved.
Performed diagnostic tests under problem 29, did test 88, 89, 90 & 92 all pointing to a bad controller. These confirmed what I already had determined as a False Error.
What I ultimately found as causing the error was that T-1 & Neutral were reversed on TB2 on the Generator side ( customer side was correct ) corrected that and the error went away and has stayed away. Amazing what you can find on a wiring schematic.

Thanks for all the help on this

Doug
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78buckshot
Congrats!
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