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    <div class="moz-cite-prefix">I've never seen battery connections
      come loose with thermal activity, as long as they had a regular
      split lock washer on.  I've gone back on our own work that is over
      13 years old, and all is still tight. As Allan noted, I have seen
      plenty of failures due to untightened, and improperly crimped
      connections.  Belleville washers would be nice, as long as they're
      not prohibitively expensive.  We used them on certain connections
      in Utility scale work.<br>
      I still use Vaseline with great results (ala my mentor Windy
      Dankoff) but I recently started using Deka battery terminal
      protection in a spray on can for higher temp applications where
      the Vaseline might melt and run off.<br>
      <br>
      <pre class="moz-signature" cols="72">R.Ray Walters
CTO, Solarray, Inc
Nabcep Certified PV Installer, 
Licensed Master Electrician
Solar Design Engineer
303 505-8760</pre>
      On 4/1/2013 3:00 PM, Allan Sindelar wrote:<br>
    </div>
    <blockquote cite="mid:5159F56B.1000303@positiveenergysolar.com"
      type="cite">
      <meta content="text/html; charset=ISO-8859-1"
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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 moz-do-not-send="true" 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 moz-do-not-send="true" 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>
        <div class="moz-signature">
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          <font face="Times New Roman, Times, serif"><b>Allan Sindelar</b></font><br>
          <small><a moz-do-not-send="true"
              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 moz-do-not-send="true"
                href="http://www.positiveenergysolar.com/"
                target="_blank"><u>www.positiveenergysolar.com</u></a><o:p></o:p></span></font>
          <p class="MsoNormal" style="margin-right: 722.25pt;"><span
              style="font-size: 10pt;"><font face="Times New Roman,
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                style=""><br>
              </b></span></p>
          <span style="font-size: 10pt;"><br>
          </span> </div>
        On 3/25/2013 2:49 PM, John Berdner wrote:<br>
      </div>
      <blockquote
        cite="mid:B448FC9E37458B469E77EA0BB954AD4702BD87B84D@mailbox01"
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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 moz-do-not-send="true"
                      class="moz-txt-link-abbreviated"
                      href="mailto:re-wrenches-bounces@lists.re-wrenches.org">re-wrenches-bounces@lists.re-wrenches.org</a>
                    [<a moz-do-not-send="true"
                      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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                <br>
                <br>
                -- <br>
                Chris Mason <br>
                President, Comet Systems Ltd<br>
                <a moz-do-not-send="true"
                  href="http://www.cometenergysystems.com">www.cometenergysystems.com</a><br>
                Cell: 264.235.5670<br>
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                align="center">
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