[RE-wrenches] Midnite Powerflo16 Enclosure Rust Issues

Fri Aug 29 07:46:26 PDT 2025

Hi Jason

I never implied anything about your install—I haven’t seen it. I was simply
sharing my direct experience with the PF16 battery installed outdoors. My
reply was meant as a general comment: that all considerations need to be
taken into account when placing outdoor-rated batteries.

If this was my install, I’d ask myself: *What can I do to make the system
work properly, keep the customer happy, and reduce any chance of callbacks?*
Personally, I wouldn’t recommend installing this, or any battery outside
without some overhead protection. That’s just how I approach
installs—always working to mitigate risks and future issues. My experience
in both Florida and Montana over the past 30 years has reinforced that
approach. That was my feedback in my last post, Not to say your install was
bad or wrong. It's your install, and I have not seen it nor is it my
business. If you took it that way it was not my intent.

That said, I stand by the fact that there are many successful installs
(including several of my own) of this battery outdoors—with no direct rain
exposure—where this has not been an issue. In cases like this, a little
WD-40 and a rag are usually enough to address the cosmetic concern. The
bigger factor, in my opinion, is simply that the enclosures are white,
which makes any surface rust far more visible than it would be on darker
cases.

Looking at the specific photos you shared:

   -

   The rear rust spot is from the mount lock-down screw hole. You cannot
   powder coat threads. A stainless screw in that location would prevent rust.
   -

   On the cover, the powder coat was removed by the countersunk screw
   during lid reassembly. Tightening the screw exposed bare steel, which will
   rust.
   -

   The amount of sand visible in the photos shows how aggressive the
   environmental conditions are at this install site.

All of these surface rust issues can be mitigated. Using stainless hardware
with a touch of anti-seize would prevent recurrence. Is this extra work?
Yes—but since batteries installed under cover typically don’t see these
issues, it may be a reasonable solution. From a manufacturing standpoint,
I’m not sure how they could solve this at a reasonable cost without passing
it along to the customer.

Manufacturers also face limitations in how they design, certify, and
produce equipment—it’s not as simple as it may look from the end-user
perspective. In regards to the "trash" remark. The PF16 carries a 15-year
warranty, which speaks to its durability and quality. It also comes with
U.S.-based support that consistently goes above and beyond, and in my
opinion, is priced fairly for what it delivers.That said, your feedback is
valuable as are the photos.

If you have ideas on how these points could be addressed at scale and at a
fair price, I’m sure MNP would be receptive to constructive suggestions.
How would you fix it?

I’m not a Midnite Power or Midnite Solar employee, so if this remains a
concern for you, I’d encourage you to reach out to them directly.

On Fri, Aug 29, 2025 at 8:40 AM Jason Szumlanski <
jason at floridasolardesigngroup.com> wrote:

> William,
>
> The attached images are indefensible. This is 2 weeks after installation
> with completely undisturbed screws from the factory. This is substandard
> quality by any reasonable interpretation.
>
> I was referring to Mark's "rusted piece of trash" comment, agreeing that
> IP65 does not guarantee cosmetic performance. That doesn't mean it is
> acceptable to sell an outdoor-rated product that becomes a rust bucket in
> short order. Only time will tell if these issues become serious. The
> purpose of my original post was to find out if anyone else is seeing
> similar issues or if this might just be a bad batch.
>
> I don't appreciate any implication that my installation, experience, or
> common sense are lacking. The product is marketed for an outdoor
> environment. Similar products that are rated and marketed in the same
> manner have not exhibited these issues virtually out of the box in my
> experience, even those on properties directly on the coast. The early signs
> of rust on these units are a justifiable concern.
>
>
> 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 Fri, Aug 29, 2025 at 8:21 AM William Bryce <
> wlbryce at pineridgeproducts.com> wrote:
>
>> 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.
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>> 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?
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>> 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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