toasted buss bar & wire

[mtdoc]

Thanks Chris I though about that also. Would like to have a good quality torque screwdriver just have to get the correct one as they vary as to the range they cover.

Maybe Ryan will pop in here and let us know what model they are using in some of the MN Video. I think they mentioned it in the video but no access to the video here on the boat. Internet connection too slow.

FWIW  I bought one of THESE a few years back and have been very happy with it.

[DMJ72]

Thanks Chris I though about that also. Would like to have a good quality torque screwdriver just have to get the correct one as they vary as to the range they cover.

Maybe Ryan will pop in here and let us know what model they are using in some of the MN Video. I think they mentioned it in the video but no access to the video here on the boat. Internet connection too slow.

The one mentioned by John in the Midnite video is the Sturtevant Richmont model :

http://www.amazon.com/Sturtevant-Richmont-810587-Limiting-Screwdriver/dp/B00JFL4DYE/ref=sr_1_2?ie=UTF8&qid=1399069171&sr=8-2&keywords=Sturtevant+Richmont

Not cheap but are supposed to be the best out there.

On my last trip to the USA, I went all over trying to find a Torque screwdriver to no avail. I think I will just order the once mtdoc listed from Amazon (especially after seeing this thread).

[mtdoc]

In addition to its price, the nice thing about the Neiko is it has a long, non metallic shaft and handle.  Makes poking it around in my ePanel easy and safe...

[DMJ72]

In addition to its price, the nice thing about the Neiko is it has a long, non metallic shaft and handle.  Makes poking it around in my ePanel easy and safe...

Thats good. Do you find it accurate? What is the shaft made out of?

[Resthome]

Been looking at this one which is actually a Snap-On tool and has good reviews.

http://www.amazon.com/gp/product/B001F7VJSE/ref=ox_sc_act_title_1?ie=UTF8&psc=1&smid=ATVPDKIKX0DER

[zoneblue]

So what size breakers *are* on those two wires?

[Westbranch]

Resthome, can't seem to get that link to work...

[Resthome]

Resthome, can't seem to get that link to work...

Yeah, that link had it for $107 and appears to be no longer available at that price. There are other places that have it a little cheaper.


http://www.amazon.com/gp/product/B001F7VJSE/ref=ox_sc_act_title_1?ie=UTF8&psc=1&smid=ATVPDKIKX0DER

[mike90045]

time to catch up on Q&A.
The cable is a coarse stranded cable (#4)
The toasted wire feeding the battery is #4, from a 3KW PV array. It is protected by a 80A breaker, used as a switch. it has never tripped.  No shorts have happened anywhere.

I think this is the likely scenario: My electrician re-used a older cable, cut it in half and tied the middle to the buss bar.  He most likely torqued it down properly, likely cutting a couple strands in the process.  The wire also most likely had a invisible layer of copper oxide on it's surface, adding to it's resistance.    Add time, and 4 years of seasonal thermal cycles, and things went bad.

What I'd like to find out from Midnight, is -
1)  is the buss labeled Battery Positive,  supposed to have only small loads tied to it ?
2) the big bolt on the 250A DC breaker, are large loads/sources supposed to tie to it ? 
    How many lugs can fit under it?
3) should there be more sizes of holes/setscrews in the buss to match wires better ? 
4) what about a different style of clamp for the wires, setscrew presses on metal plate which locks in the wires?
5) Adding a label, advising  annual re-torque of connections ?


Has anyone had any close calls like this in the past, or is this so rare it's not worth a second glance and I should just wash my pants.

[zoneblue]

The toasted wire feeding the battery is #4, from a 3KW PV array. It is protected by a 80A breaker, used as a switch. it has never tripped.  No shorts have happened anywhere.

Im confused. PV should either be connected to the PV+ bus or to the controller direct. If by '3kW PV' you mean the output of the charge controller, then, thats usually lugged onto the inverter breaker. Thats a connection you want real nice.

A charge controller tends to put out a spikyish waveform, and can see high sweep surges. It will also confuse the controller having any high resistance points between it and the bank.

[Westbranch]

ZB, good point...  I noted on the attached pic that both the  PV in buss and the Batt + buss are the same size...

[mike90045]

    Im confused. PV should either be connected to the PV+ bus or to the controller direct. If by '3kW PV' you mean the output of the charge controller, then, thats usually lugged onto the inverter breaker. Thats a connection you want real nice....

PV comes into a 80A PV breaker, then loops out to the ChgCtrl, back into a 80A breaker, then to the bus labeled
Battery Plus Bus.  Now that my 2nd array is installed, it too comes into the box, to a breaker, out to ChgCtrl, back in through a breaker, and then to the  Battery Plus Bus too.  So now there are 2 controllers feeding the buss.  So there is a 2Kw & a 3Kw array feeding the buss (arrays are about 30 degrees offset so they don't peak at the same time).  So
there could be 90A on that buss, that then feeds the terminal on the back of the breaker.

So does the Midnight bolt on the breaker, have enough length, to stack 3 lugs under it ?  PV1, 2, & a cable to the buss?

Should I run the 3Kw array to the breaker bolt and stack a lug on it to go to the buss ?

[Vic]

MidNite offers the Big Busbar that mounts onto the stud of a large E-frame breaker:
http://www.midnitesolar.com/productPhoto.php?product_ID=208&productCatName=Busbars&productCat_ID=17&sortOrder=2&act=p

Not inexpensive,  but manly.    FWIW,  Vic

[dgd]

MidNite offers the Big Busbar that mounts onto the stud of a large E-frame breaker
Not inexpensive,  but manly.    FWIW,  Vic

Now thats a proper bus bar. Where do I get one? can't see it on naws/alte

dgd

[dgd]

So does the Midnight bolt on the breaker, have enough length, to stack 3 lugs under it ?  PV1, 2, & a cable to the buss?

Should I run the 3Kw array to the breaker bolt and stack a lug on it to go to the buss ?

Yes, the breaker lug is long enough for these and unless you have smaller +ve loads you may not need to bother with that short +ve bus and its #6 cable to the breaker lug.

dgd