Op had bad crimp on one end and what appears be bus bar - washer sandwich other end ….heat meeting in middle of probable loose - improper applied snap push on cable connector. Op was only concerned with documentation after the fact not before.
Wow, that looks awful!
Also, it turns out that the (hundred amp?) connectors on the ChargeVerter GC are not Degson. They get warm (not hot) as do the connecting cables supplied with the ChargeVerter, but nothing has melted yet. also, unlike the Degson connectors on the batteries, you can plug positive into negative and vice versa.
That would be bad …. Those connectors are on charge inverter? Got any pictures? Thanks
That is completely wrong, the was no washer between the bussbar and lug. You people are just making things up.
No, That is not a washer it is damaged metal from the heat, again this is a precautionary post. Don't make s stuff up to minimize the damage that can be done from a bad connector.
I get what you are saying, but why is that melted connector on an angle from the busbar? Is that something that happened during disassembly?
Kinda defensive?
I guess it adds significant value to the conversation to mention that using washers is not good and bad crimps are also a potential point of failure.
It is obvious that the bussbar and connectors were disassembled from the battery pack because there are no pictures of the battery pack. Everybody should have realized that because where is the battery pack in the picture?
It looks like you had the same problem I had.
The optical illusion strikes again.
That is hilarious that you have to validate your observation. I have said from the get go that there was no washer there. But the trolls will troll! Furthermore another owner has had a similar occurrence. Everyone beware that these connectors could potentially have an issue that could result in a failure.
Only pointing out that there's no washers between the busbar there's plenty of other things have been mentioned, though personally I would have added some spring washers to the rear between the bolt head and the bus bar. From the above photo it shows some annealing between the connector and busbar, we still can't be sure the connector was totally at fault( yes we know they are underpriced copies).
That is the bottom of the bussbar. I figure that most people realize there is a top and bottom view. I guess you don't know anything about these batteries because there is a lock washer between the bolt and flat washer. These are the original unaltered photos below. Anybody who is reading this thread please disregard all the nonsensical conjecture and realize the potential hazards that can happen.
That is not how the system works! You cant exceed the maximum output and input amperage set in your inverter settings. Unless there is a problem!!! In this case there were only 3 batteries in parallel. For this particular setup it was set at 0.20c discharge and charge amperage or max 160Amps. A great feature of the computer based monitoring system is a BMS history log. After anylizing the BMS's histories, the maximum charging/discharging amperage was 47amps from any one battery, so times that by 3 batteries in parallel it was 140 amps charging current coming from the MPPT or being discharged to the inverter.
Your right I know nothing of these connectors, I use a lug and busbar/terminal for all high amperage connections, though it doesn't stop the decades of experience I have in manufacturing engineering from being inquisitive. You only needed to add that there was infact a spring washer which doesn't seem to have made the contact any better hence the burning between where the connection and busbar meet. It's obvious that there was excessive heat in the poor quality quick connect you used, I'm just trying to ascertain whether that was the primary point of failure or the secondary.
I have thanked and acknowledged the great amount of input in this thread, if one person gets value from any of this. A good service has been done.
