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<div class="moz-cite-prefix">John,<br>
I respect your experience and your advice, and have a few
questions related to this post.<br>
<br>
I have seen problems in the past with failed and high-resistance
battery terminal connections. Usually it's the result of corrosion
buildup on unprotected terminals installed by a homeowner or a
lowball installer, but I can recall at least one instance in which
one of our installers didn't tighten a terminal sufficiently, or
else the connection loosened as you described below, and it melted
the terminal and caused a system failure - which we covered under
our installation warranty. But I have never seen advice as
specific as yours on actual terminal connection materials and
procedure.<br>
<br>
What corrosion inhibiting grease do you recommend? I have seen
Vaseline used for decades, and don't think I have ever seen a
failure. We have used QuickCote for years, with the brush-in-can,
but it's tedious. <br>
<br>
I found two versions of SS Belleville washer at fastenal.com:<br>
5/16" curved spring washer at
<a class="moz-txt-link-freetext" href="http://www.fastenal.com/web/products/details/33192?searchMode=productSearch&rfqXref=&rfqKeyword=&rfqId=&rfqLineId=">http://www.fastenal.com/web/products/details/33192?searchMode=productSearch&rfqXref=&rfqKeyword=&rfqId=&rfqLineId=</a><br>
5/16" Belleville washer at
<a class="moz-txt-link-freetext" href="http://www.fastenal.com/web/products/details/71239?searchMode=productSearch&rfqXref=&rfqKeyword=&rfqId=&rfqLineId=">http://www.fastenal.com/web/products/details/71239?searchMode=productSearch&rfqXref=&rfqKeyword=&rfqId=&rfqLineId=</a><br>
The former has radial serrations, but I think the latter is what
you're recommending - yes?<br>
<br>
You write "locknut" below - are you recommending a standard 5/16"
SS nut, or a specific type of locknut like a Nylock?<br>
<br>
Thanks for going into a bit more detail for us. I'd like a bit
more peace of mind. I actually a bit about 14 year old banks
losing one string and overloading another...<br>
Allan<br>
<br>
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<font face="Times New Roman, Times, serif"><b>Allan Sindelar</b></font><br>
<small><a href="mailto:Allan@positiveenergysolar.com"><font
face="Times New Roman, Times, serif" color="#000099"><u>Allan@positiveenergysolar.com</u></font></a></small><font
face="Times New Roman, Times, serif"><br>
<span style="font-size: 10pt;">NABCEP Certified Photovoltaic
Installer<br>
NABCEP Certified Technical Sales Professional<br>
New Mexico EE98J Journeyman Electrician<br>
Founder and Chief Technology Officer<br>
<b>Positive Energy, Inc.</b><br>
3209 Richards Lane (note new address)<br>
Santa Fe, New Mexico 87507<br>
<b>505 424-1112</b><br>
<a href="http://www.positiveenergysolar.com/"
target="_blank"><u>www.positiveenergysolar.com</u></a><o:p></o:p></span></font>
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</span> </div>
On 3/25/2013 2:49 PM, John Berdner wrote:<br>
</div>
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<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D">I
concur with William’s recommendations and would add a
couple of things.<o:p></o:p></span></p>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D"><o:p> </o:p></span></p>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D">Only
use stainless steel hardware for all battery connections.<o:p></o:p></span></p>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D">Wire
brush connection surfaces prior to mating.<o:p></o:p></span></p>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D">Use
corrosion inhibiting grease on all fittings after making
them (to seal out air).<o:p></o:p></span></p>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D"><o:p> </o:p></span></p>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D">Lastly,
It is a good idea to use stainless Belleville washers
(cupped spring washers) in current carrying connections.<o:p></o:p></span></p>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D"><o:p> </o:p></span></p>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D">Bolt
head, washer, Battery terminal, washer, Belleville washer,
locknut.<o:p></o:p></span></p>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D">The
spring washer maintains clamping force as the connection
expands and contracts (thermally).<o:p></o:p></span></p>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D">They
are very common place in high current bus bar connections
but I rarely see them used on batteries.<o:p></o:p></span></p>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D"><o:p> </o:p></span></p>
<div>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D">Best
Regards,<o:p></o:p></span></p>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D"><o:p> </o:p></span></p>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D">John
Berdner<o:p></o:p></span></p>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D">General
Manager, North America<o:p></o:p></span></p>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D"><o:p> </o:p></span></p>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D">SolarEdge
Technologies, Inc.<o:p></o:p></span></p>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D">3347
Gateway Boulevard, Fremont CA 94538 USA </span><b><i><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#C00000">(*Please
note of our new address.)</span></i></b><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D"><br>
T: 510.498.3200, X 747<o:p></o:p></span></p>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D">M:
530.277.4894 <o:p></o:p></span></p>
</div>
<p class="MsoNormal"><span
style="font-size:11.0pt;font-family:"Calibri","sans-serif";color:#1F497D"><o:p> </o:p></span></p>
<div>
<div style="border:none;border-top:solid #B5C4DF
1.0pt;padding:3.0pt 0in 0in 0in">
<p class="MsoNormal"><b><span
style="font-size:10.0pt;font-family:"Tahoma","sans-serif"">From:</span></b><span
style="font-size:10.0pt;font-family:"Tahoma","sans-serif"">
<a class="moz-txt-link-abbreviated" href="mailto:re-wrenches-bounces@lists.re-wrenches.org">re-wrenches-bounces@lists.re-wrenches.org</a>
[<a class="moz-txt-link-freetext" href="mailto:re-wrenches-bounces@lists.re-wrenches.org">mailto:re-wrenches-bounces@lists.re-wrenches.org</a>] <b>On
Behalf Of </b>William Miller<br>
<b>Sent:</b> Monday, March 25, 2013 12:41 PM<br>
<b>To:</b> RE-wrenches<br>
<b>Subject:</b> Re: [RE-wrenches] GSCM-mini with Honda
EM5000SX<o:p></o:p></span></p>
</div>
</div>
<p class="MsoNormal"><o:p> </o:p></p>
<p class="MsoNormal">Eric:<br>
<br>
The generator-based charging may impose higher currents into
the batteries than either PV charging or inverter
consumption, triggering the problem. <br>
<br>
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.<br>
<br>
William Miller<br>
<br>
At 09:40 AM 3/25/2013, you wrote:<br>
<br>
<o:p></o:p></p>
<p class="MsoNormal"><span
style="font-size:10.0pt;font-family:"Arial","sans-serif"">Larry,<br>
</span> <br>
<span
style="font-size:10.0pt;font-family:"Arial","sans-serif"">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?<br>
</span> <br>
<span
style="font-size:10.0pt;font-family:"Arial","sans-serif"">Eric
Stikes<br>
SunHarvest Solar<br>
</span> <br>
<br>
<o:p></o:p></p>
<blockquote style="margin-top:5.0pt;margin-bottom:5.0pt">
<p class="MsoNormal">We install solar pool pumps quite
frequently here in the Caribbean. We use Sunpumps -
excellent company, great support. Email Joe Lines joe@<a
moz-do-not-send="true" href="mailto:joe@sunpumps.com">sunpumps.com</a>
for design assistance, he is very helpful.<br>
<br>
<br>
On Wed, Feb 20, 2013 at 1:02 PM, William Korthof <<a
moz-do-not-send="true" href="mailto:wkorthof@gmail.com">wkorthof@gmail.com</a>>
wrote:<br>
<br>
<o:p></o:p></p>
<p class="MsoNormal" style="margin-bottom:12.0pt">A few
questions. <br>
<br>
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? <br>
<span style="color:#888888"><br>
William Korthof<br>
Sustainable Solutions Partners<br>
<br>
</span><br>
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Check out participant bios:
<a class="moz-txt-link-abbreviated" href="http://www.members.re-wrenches.org">www.members.re-wrenches.org</a>
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