[CharlieJ]

Captden-Gord has it right. Your charging problem has nothing to do with the instrumentation or the readings from that instrumentation on your genset (sorry donradcliffe). Look at the table in the Xantrex Technote that I posted earlier. The folks at Xantrex have taken waveform, power factor, peak voltage, etc. and condensed it into a table for the minimum sized genset required to run their inverter/chargers at near maximum output.

If you want to do the math (using Gord's formulae); your 5.5 kW genset (120 VAC @ 45.8 amps resistive load; "real power" noted by the kW units) becomes a: 120 VAC x 45.8 x 0.7 = 3.85 kVA ("apparent power", noted by kVA) genset when supplying the inductive charger function of your inverter/charger. And this does not take into account the debillitating effects caused by poor or marginal genset voltage and frequency sag management and stability, waveform, etc.

Before changing the Freedom, you should try and install the load correction capacitor that the Technote recommends. It should cost you about $35.00 and is probably worth the effort.

This all being said, your genset is too small to drive a Xantrex Freedom Inverter/Charger at anywhere near its rated capacity.

Hope this clarifies.