Using both LApp and MyMidnite helped in diagnosing a well hidden problem

[Westbranch]

I just want to give a great  THANK YOU! to MidNite Solar for providing the 2 monitoring tools with the purchase of a Classic...

Without them I would not have been made aware of a hidden, potentially dangerous  wiring problem.

The cause was an under tightened screw on the Positive buss bar, in an Epanel, that connects the PV to the battery.

Being  snug but not hard tight,( might one say a bit loose?), when I recently swapped Classics to help diagnose an under charge issue, very short BULK and early Absorb, I tried  eliminating the obvious causes to no definite answer.

So I started to systematically check for loose connections or bad wiring for voltage drops.  Here is what i found inside the Epanel

[BobWhite]

I think ill switch to ferrules on all my connections with screw type connections!!

Walt

[mike90045]

Sadly, this is not the first time for these bars heating up.   Mine seemed well torqued (bear to get loose) 

a supplier for ferrules:
http://www.ferrulesdirect.com/Merchant2/merchant.mvc?Screen=CTGY&Store_Code=FD&Category_Code=UNFERR

[BobWhite]

Sadly, this is not the first time for these bars heating up.   Mine seemed well torqued (bear to get loose) 

a supplier for ferrules:
http://www.ferrulesdirect.com/Merchant2/merchant.mvc?Screen=CTGY&Store_Code=FD&Category_Code=UNFERR

Thank you for posting Ferrulsdirect!!! was wondering were I would find the 4/O cable ferrules as I haven't found them to date.

Walt

[Westbranch]

Mike is there any reason not to use these pin terminals?  Seems one would be assured they will fit the opening.

http://www.ferrulesdirect.com/electrical/PINTRMNLS.htm

[BobWhite]

Mike is there any reason not to use these pin terminals?  Seems one would be assured they will fit the opening.

http://www.ferrulesdirect.com/electrical/PINTRMNLS.htm

WB are you using the pin terminals? I have found that they break at the point between the barrel and the pin as it is the point of the least material or the weakest point. I guess if there is proper support that wont be a problem but I find its not always possible in some applications. 

[Westbranch]

No, but I was thinking it would be a better fit into the hole. 

I can't imagine in a stationary (E-Panel) that there would be any movement..? In a Boat I can see it happening , vibration and all.

[BobWhite]

I would agree with you on that, as you probably know I'm in the marine field, I think if you can support the connection it would be fine but I still don't like the week link here! I've seen to many separate without a good cause other than it is the weakest point in the connection.

[Westbranch]

yes, I agree about the weak point in the link.

I noticed on some of the 2 ga. one the @^# for a crimper ans it does a trapezoidal crimp but could not find a pic of the finished product...

http://www.ferrulesdirect.com/terminal/1006/FD0401L.htm

here is a pdf showing a Trapezoidal shape crimp

http://www.farnell.com/datasheets/7151.pdf

[BobWhite]

You are awesome, Keep me thinking! I have a few crimpers as you have posted, I would like to see the trapezoidal crimp!!I would think it would a lot better than the square crimp. that will also become loose in  round hole!!