[RE-wrenches] Midnite Powerflo16 Enclosure Rust Issues

Fri Aug 29 05:20:46 PDT 2025

As installers, our decisions directly impact the long-term success of a
project and the satisfaction of the customer. The PF16 case is made from
steel, and like all non-stainless steel enclosures, if the powder coat is
scratched the underlying metal can rust. The white finish can make any rust
more visible.

All manufacturers use steel for outdoor battery cases to meet UL testing
requirements. When exposed to direct sunlight, the powder coat will
gradually degrade—just like standard exterior paint—so some level of
maintenance should always be expected. This applies to all outdoor-rated
batteries, not just the MNP PF16.

I installed two PF16 units outdoors in Florida, about 20 miles from the
coast. They were mounted on the side of a barn with a low overhanging roof
for protection from direct rain. After more than two years, they still look
good with no signs of rust. By contrast, if the same batteries were placed
outdoors with no overhead protection, I would expect to see some rust. That
is simply the reality with steel construction, whether we’re talking about
outdoor-rated batteries, lawn equipment, tractor / implements, or trailers.

The key is proper installation: ensuring the top is secured and the seal is
intact, using seal-tight conduit entries, and following the IP65 rating
guidelines. Cosmetic choices—such as placement and exposure—are typically
decided between the installer and the customer, and this is where
experience and common sense come into play.

Based on their certification, I am confident Midnite Power will stand
behind and warranty any unit that fails from water ingress when installed
correctly. But it’s also fair to say that if the MNP battery design does
not meet your needs, then perhaps it isn’t the right choice for your
project.

A stainless steel case would avoid rust entirely, but the cost would be so
high that few customers would buy them. At the price point these batteries
are offered, you will be hard pressed to find an alternative that would
perform better under the same conditions.

Have you reached out to Midnite Power directly to discuss your concerns?
I'm sure using the professional term "trash" will help the support call go
well.

On Fri, Aug 29, 2025 at 5:38 AM Jason Szumlanski via RE-wrenches <
re-wrenches at lists.re-wrenches.org> wrote:

> I agree with the fact that an IP rating doesn't have anything to do with
> cosmetic performance.
>
> I also agree with the "trash" part.
>
> Any reasonable person would expect a product advertised as "Environment:
> Outdoor," with no other guidance, to not rust in a matter of weeks, absent
> physical damage.
>
> Even if I were to "protect" these batteries somehow, whatever that means,
> even occasional mists of water are likely to continue to cause rust. I now
> have serious concerns about this product.
>
>
> Jason Szumlanski
> Principal Solar Designer | Florida Solar Design Group
> NABCEP Certified Solar Professional (PVIP)
> Florida State Certified Solar Contractor CVC56956
> Florida Certified Electrical Contractor EC13013208
>
> On Thu, Aug 28, 2025, 10:52 PM Mark Frye via RE-wrenches <
> re-wrenches at lists.re-wrenches.org> wrote:
>
>> IP ratings are cumulative so each rating level includes all previous
>> level of performance. IP62 is good enough for “rain”. IP65 turns that into
>> howling raging jets of water.
>>
>>
>>
>> If the manufactures says the product is IP65 rated and gives no other
>> specific installation instruction in the product manual, then there should
>> be no need for additional “protection” from water. I saw this product
>> advertised as “outdoor, wall mounted” on one web site, which is consistent
>> with an IP65 rating.
>>
>>
>>
>> So where does that leave you with this manufacture?
>>
>>
>>
>> Well you don’t have a leg to stand on if you are in the warranty period
>> and no water enters the enclosure after being subjected to jets of water.
>>
>>
>>
>> The thing may look like a rusted piece of trash but that is not what an
>> IP65 rating promises.
>>
>>
>>
>> BTW
>>
>>
>>
>> Bentek includes a clause that any enclosure must receive touch up paint
>> to prevent rust in order for them to honor the warrenty.
>>
>>
>>
>>
>>
>> *From:* RE-wrenches <re-wrenches-bounces at lists.re-wrenches.org> *On
>> Behalf Of *Chris Sparadeo via RE-wrenches
>> *Sent:* Thursday, August 28, 2025 6:40 PM
>> *To:* RE-wrenches <re-wrenches at lists.re-wrenches.org>
>> *Cc:* Chris Sparadeo <sparadeo.chris at gmail.com>
>> *Subject:* Re: [RE-wrenches] Midnite Powerflo16 Enclosure Rust Issues
>>
>>
>>
>> I’ve been reflecting recently about IP ratings and my new opinion is that
>> IP55 and IP65 ingress ratings mean “somewhat outside”. Many manufacturers
>> with these mentioned ratings (which are identical for moisture ingress and
>> vary only slightly for dust ingress) will explicitly say that their product
>> cannot be exposed to direct rainfall or moisture…which doesn’t sound very
>> outdoor rated to me. Take this IP65 rated battery manufacturer’s
>> installation recommendations for example:
>>
>> “The Battery Pack must be kept away from direct sunlight and rain or
>> other sources of moisture.
>>
>> This applies to both indoor and outdoor installations. Even if installed
>> indoors such as basement or garage, direct sunlight and rain or other
>> sources of moisture may still penetrate, so it is essential to protect the
>> Battery Pack from direct sunlight and rain or other sources of moisture”.
>>
>>
>>
>> I get the sunlight part, but protecting an ESS from moisture when
>> installed outdoors seems like a tall order.
>>
>>
>>
>>
>>
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>> On Thu, Aug 28, 2025 at 9:16 PM Jason Szumlanski via RE-wrenches <
>> re-wrenches at lists.re-wrenches.org> wrote:
>>
>> I don't know what you mean by unprotected. That is exactly what an IP65
>> rating suggests - outdoors, subject to the elements. Nowhere does it say in
>> the product literature thay it must be "protected," whatever that means.
>> Protected against the environment that it is rated to be in? Seriously?
>>
>>
>>
>> If it can get wet, it shouldn't rust around the undisturbed factory
>> installed screws in a couple of weeks. If this is how the product is going
>> to be, it is totally unsuited for OUTDOOR installations, which is exactly
>> where it says it can be installed on the spec sheet.
>>
>>
>>
>>
>> Jason Szumlanski
>>
>> Principal Solar Designer | Florida Solar Design Group
>> NABCEP Certified Solar Professional (PVIP)
>> Florida State Certified Solar Contractor CVC56956
>>
>> Florida Certified Electrical Contractor EC13013208
>>
>>
>>
>> On Thu, Aug 28, 2025, 8:50 PM William Bryce <
>> wlbryce at pineridgeproducts.com> wrote:
>>
>> Hi Jason
>>
>>
>>
>> Rust will have no effect on the IP65 rating of the battery.
>>
>>  The batteries are intended for  outdoor protected install only.
>> Because the batteries are heavy, installers can easily nick or damage the
>> powdercoat on the battery leading to rust. Because the battery is white it
>> shows the rust way easier than other outdoor rated batteries.
>>
>>
>>
>> The case of the battery must be made from* steel *because the UL rating
>> certifies if the battery was to have a meltdown, no flame can escape from
>> the battery
>>
>>
>>
>> The manual needs to better specify the protected install.
>>
>>
>>
>> Are the batteries installed outside unprotected?
>>
>>
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>> On Thu, Aug 28, 2025 at 7:54 PM Jason Szumlanski via RE-wrenches <
>> re-wrenches at lists.re-wrenches.org> wrote:
>>
>> We have five PF16 installed outdoors at a home. It has been only 2 weeks
>> and I'm seeing rust forming around some cover screws (both the top cover
>> and front cover). The brackets are also showing some rust spots, and under
>> the rims of the top cover I'm seeing rust spots that look like they are
>> from small metal shavings. We also found minor rust around a prepunched
>> knockout immediately after removing the protective plastic cap.
>>
>>
>>
>> This all happened after they had been mounted outdoors for two weeks, but
>> no conduit had been installed yet and the top covers hadn't even been
>> opened once.
>>
>>
>>
>> Is anyone else seeing these issues? I'm pretty concerned that my customer
>> won't accept this early defect, and I have lots of outdoor installations
>> planned for other customers.
>>
>>
>>
>> P.S. This is not a coastal location (although all of Florida is kind of
>> coastal). Regardless, it's IP65 and should withstand a typical outdoor
>> installation.
>>
>>
>>
>>
>>
>> Jason Szumlanski
>>
>> Florida Solar Design Group
>>
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