Connecting the WBjr to Classic

[Westbranch]

I would like to know how big (diameter) the hole we need to use for connecting the purple wire to Aux2 is?

I was at our local Wholesale electrical supplier and his display rack had some nice insulated flat blade screwdrivers about 6mm wide..., want to buy one if it will work in that small hole

[Vic]

Wb,

Believe that you are referring to the Aux connector,  and the nominal ID of the plastic that surrounds the Aux 2 terminal contact.

I do not have the diameter of that hole,  but it is quite small.  Used a screwdriver from a Jewler's Screwdriver set.

To me,  6 MM is just under 0.25 inches.   This would many times larger than is the Aux connector recess.

Will try to Claiper the approx. blade width.   You could just place some Shrink Fit on all but the tip of the screwdriver shaft,  for insulation ...

More Later,     Vic

[Westbranch]

Wb,

Believe that you are referring to the Aux connector,  and the nominal ID of the plastic that surrounds the Aux 2 terminal contact.

Vic, yes, that's the beast I need to get at...

[Vic]

OK,  Wb,

The blade of a screwdriver that fits the hole in the connecter is called a 3/32" (flat blade) screwdriver.   It Calipers at 0.102 ",  and is just about the largest that one could use.

So,  would guess that a 2.5 MM would be the largest one might want to use.

To me,   this Aux connector is out in the open,  and an un-insulated screwdriver should be fine for almost any of us to manipulate in the area,  without risk.

Good that you are asking,  as many off-grid,  rural sites do not have a sufficiently small flat blade screwdriver for this task.

Good Luck,    Vic

[Westbranch]

   Thanks for those measurements Vic. Now it's findable.

as many off-grid,  rural sites do not have a sufficiently small flat blade screwdriver for this task

That is exactly what happened to me , I found a sewing machine screwdriver and it saw the flat side of a file till it would fit, don't tell the boss  , but I want a dedicated one for that task and a red/orange WERA one caught my eye... now to see if it IS small enough 

[russ_drinkwater]

You can make a usable small screw driver out of oxy welding wire in a pinch.
I have often made small tools for removing cam shaft lifters and the like from welding wire.
If you need something harder then us a small diameter good quality arc welder road and crush the flux off it and hammer and file to size.
You can harden as well by heating to cherry red a few times and plunging your newly made screwdriver into motor oil to harden it.
The problem with living in the bush you have to make do or make a lot of gear when it is 400 kms round trip to the nearest large hardware store in a city. Or get it online and then wait.

[Westbranch]

Russ, SWMBO has a fit whenever I want to keep something, 'cause I will need it 5 min. after I throw it out...' , she also does not know    I modified her smallest sewing machine screwdriver  with a round chainsaw file to get it to work...  short on suitable materials and proper tools... vice, flat file, bench, ...etc...  99% of what I work with is made of wood...

  so I have to replace that small driver soon 

[russ_drinkwater]

Mate, buy her a small set of screwdrivers from walmart or the like for christmas!!!!!
That will be one present off the list.
Being that it will be winter there at that time you may experience the icy chill from snow fed breeze
Send me a photo of that lol.
Not sure where I can mount my whizbang as my battery box is outside and I do not want the unit in the box with FLA
batteries or out in the weather.
If I mount it on my board inside I have no way of "splicing" it into the power cable from the inverter.

[Westbranch]

Don't the (-)  cables from/to the battery come inside the house to the CC?
Is there a  Buss bar in that line ?
E-panel type power center?

just taking stabs at possibilities.. 

[russ_drinkwater]

There are the cables from the CC going to batteries both + and -.
For some reason I had it in my mind it need to be the battery to inverter - cable.
I have not read the install instructions I downloaded yet.

[Westbranch]

In order for the WBjr to 'monitor ' all traffic into and out of the battery, the shunt and WBjr need to be the last attachment to the Neg battery cable prior to connecting to the Neg batt. terminal....

http://www.midnitesolar.com/productPhoto.php?product_ID=519&productCatName=Charge%20Controllers%20-%20Classics&productCat_ID=21&sortOrder=9&act=pc

look at this pic of the WBjr, the batt. neg goes to the left and nothing else... all other connections are made on/to the right hand post on the top of the shunt, or a buss bar...

hth

[russ_drinkwater]

Yes I have seen that and understand how it needs to be connected.
The problem I have is the only suitable place (cable wise) is outside near the battery box.
I will have to make up some sort of sheltered "box" for the shunt and whizbang to live in.