I concur with William's recommendations and would add a couple of things. Only use stainless steel hardware for all battery connections. Wire brush connection surfaces prior to mating. Use corrosion inhibiting grease on all fittings after making them (to seal out air).
Lastly, It is a good idea to use stainless Belleville washers (cupped spring washers) in current carrying connections. Bolt head, washer, Battery terminal, washer, Belleville washer, locknut. The spring washer maintains clamping force as the connection expands and contracts (thermally). They are very common place in high current bus bar connections but I rarely see them used on batteries. Best Regards, John Berdner General Manager, North America SolarEdge Technologies, Inc. 3347 Gateway Boulevard, Fremont CA 94538 USA (*Please note of our new address.) T: 510.498.3200, X 747 M: 530.277.4894 From: re-wrenches-boun...@lists.re-wrenches.org [mailto:re-wrenches-boun...@lists.re-wrenches.org] On Behalf Of William Miller Sent: Monday, March 25, 2013 12:41 PM To: RE-wrenches Subject: Re: [RE-wrenches] GSCM-mini with Honda EM5000SX Eric: The generator-based charging may impose higher currents into the batteries than either PV charging or inverter consumption, triggering the problem. Melted battery terminals are not uncommon. You must have washers under your bolt heads with lead flanges. Otherwise the bolt heads sink into the lead, loosening connections. All mating surfaces need to be newly wired brushed just before assembly. Battery connections need to be re-torqued annually. William Miller At 09:40 AM 3/25/2013, you wrote: Larry, Thanks for your reply. For some reason the schematic I received from the tech at Atkinson did not show any wires being connected to pins 9 & 10 and as I'm a literalist I did not make those connections. After I received your (and other) feedback I connected gen power to those pins and the AGS seemed to function fine. Within 2 days the customer called me back saying his genny was shutting off after 20 mins of runtime. I told him to disconnect or reprogram one system component at a time to find the fault source. Before a fault source was determined, he observed that two batteries in his bank were experiencing the "battery terminals melting into the battery casing" (as was texted to me by the customer). I have no idea how a GSCM interface would cause or allow an overcurrent fault at the batteries but the timing of the installation seems to indicate that the AGS is at fault. Ever heard of this before? Eric Stikes SunHarvest Solar We install solar pool pumps quite frequently here in the Caribbean. We use Sunpumps - excellent company, great support. Email Joe Lines j...@sunpumps.com<mailto:j...@sunpumps.com> for design assistance, he is very helpful. On Wed, Feb 20, 2013 at 1:02 PM, William Korthof <wkort...@gmail.com<mailto:wkort...@gmail.com>> wrote: A few questions. I have a customer who really wants a solar-direct pool pump for his home. Medium size in-ground pool and I'd like the pump to be strong enough to lift to the solar pool panels (12 ft lift above pool level). I'd like to offer him hardware that is at least one notch above experimental beta-test. I remember the SunCentric from several years ago, but not sure how durable that turned out, and I was having trouble a vendor for it now. Any suggestions for today with some favorable track record? Or suggestions on what to avoid? William Korthof Sustainable Solutions Partners _______________________________________________ List sponsored by Home Power magazine List Address: RE-wrenches@lists.re-wrenches.org<mailto:RE-wrenches@lists.re-wrenches.org> Options & settings: http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org List-Archive: http://lists.re-wrenches.org/pipermail/re-wrenches-re-wrenches.org List rules & etiquette: www.re-wrenches.org/etiquette.htm<http://www.re-wrenches.org/etiquette.htm> Check out participant bios: www.members.re-wrenches.org<http://www.members.re-wrenches.org> -- Chris Mason President, Comet Systems Ltd www.cometenergysystems.com<http://www.cometenergysystems.com> Cell: 264.235.5670 Skype: netconcepts ________________________________ _______________________________________________ List sponsored by Home Power magazine List Address: RE-wrenches@lists.re-wrenches.org<mailto:RE-wrenches@lists.re-wrenches.org> Options & settings: http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org List-Archive: http://lists.re-wrenches.org/pipermail/re-wrenches-re-wrenches.org List rules & etiquette: www.re-wrenches.org/etiquette.htm<http://www.re-wrenches.org/etiquette.htm> Check out participant bios: www.members.re-wrenches.org<http://www.members.re-wrenches.org> <EM4000SX_MINI-01.PDF>_______________________________________________ List sponsored by Home Power magazine List Address: RE-wrenches@lists.re-wrenches.org<mailto:RE-wrenches@lists.re-wrenches.org> Change email address & settings: http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org List-Archive: http://lists.re-wrenches.org/pipermail/re-wrenches-re-wrenches.org List rules & etiquette: www.re-wrenches.org/etiquette.htm<http://www.re-wrenches.org/etiquette.htm> Check out participant bios: www.members.re-wrenches.org<http://www.members.re-wrenches.org> ________________________________ _______________________________________________ List sponsored by Home Power magazine List Address: RE-wrenches@lists.re-wrenches.org<mailto:RE-wrenches@lists.re-wrenches.org> Change email address & settings: http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org List-Archive: http://lists.re-wrenches.org/pipermail/re-wrenches-re-wrenches.org List rules & etiquette: www.re-wrenches.org/etiquette.htm<http://www.re-wrenches.org/etiquette.htm> Check out participant bios: www.members.re-wrenches.org<http://www.members.re-wrenches.org/> _______________________________________________ List sponsored by Home Power magazine List Address: RE-wrenches@lists.re-wrenches.org<mailto:RE-wrenches@lists.re-wrenches.org> Change email address & settings: http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org List-Archive: http://lists.re-wrenches.org/pipermail/re-wrenches-re-wrenches.org List rules & etiquette: www.re-wrenches.org/etiquette.htm<http://www.re-wrenches.org/etiquette.htm> Check out participant bios: www.members.re-wrenches.org<http://www.members.re-wrenches.org/> Miller Solar Voice :805-438-5600 email: will...@millersolar.com<mailto:will...@millersolar.com> http://millersolar.com <http://millersolar.com/>License No. C-10-773985 CONFIDENTIALITY NOTICE: This e-mail and its attachments are intended only for the use of the individual or entity who is the intended recipient and may contain information that is privileged, confidential and exempt from disclosure or any type of use under applicable law. 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