Absorb cycle is too short

[dgd]

So you have that 60amp breaker connected to the Classic output and the other side to that bus connector?
Since you now have 3 strings of PVs input , about 1.5kw, to the Classic then the output at 24volts may exceed the breaker rating. Does the breaker get warm or hot?
I agree with Larry, but would also recommend getting that breaker replaced with a 100amp Carling type and using #4 cable with crimped ring lugs to wire from the 100a breaker to the post on the 175A inverter breaker. Forget that small bus connector.
Maybe also #4 fine multistrand from the 100a breaker to the Classic's +Ve output.
The breaker upgrade becomes more important if you add that 4th array string

Dgd

[ClassicCrazy]

Probably those wires having been loose oxidized over time , and then the resistance value went up as that happened until they got hot .

I am thinking the only reason Midnite used that connector is because it is easy plug and play for people to connect their wires to. Best to eliminate it - and I agree with dgd - if you are ever going to add more power update that breaker to 100 amps.

Larry

[ClassicCrazy]

I bought one of these inexpensive hydraulic wire crimpers - they don't make the prettiest crimps sometimes cause it smashes out the sides of the die , but it does a good job of making air tight connection that won't ever go bad.
http://www.harborfreight.com/hydraulic-wire-crimping-tool-66150.html

[Westbranch]

I concur about changing out the CB,  for the winter hibernation period I will throw the breaker& selector switch and put the 'added' array back on the other bank.

Yes those hydraulic crimpers are a handy  tool, got mine in Can$ with a bit of surfing... hard to filter to just Canadian based sellers ., at times...

Fitting in a Carling breaker may be a bit of a go as it was not designed for a surface mount.

[ClassicCrazy]

on my midnite minipv disconnect it came with two different ways to mount the circuit breaker - the panel mount like you have would fit five  or the bigger 100 amp type I think only space for three .
Larry

[Resthome]

And with panel mount 100 amp CB you don't have to be concerned with polarity like you do on those din rail breakers. That is what I am using on my set up and haven't had any issue with connections. Crimped ring connectors are the only way to go IMHO.

[mike90045]

On another board, I mentioned my issues with buss bars and #4 wires, my thread here
http://midnitesolar.com/Forum/index.php?topic=1821.msg16448#msg16448

I really don't like the setscrew into the wire bundle, it might be fine on a solid wire, but it just seems to splay half the strands away from good contact, site heats up....  downhill from there.