I would no longer use either the BMS or the charge controller for voltage values only the BMS for current. I would check the battery terminals and the charger terminals with a voltmeter. You have no idea if either of those are accurate, and even if your voltmeter is inaccurate, it should be relatively accurate such that the difference between the two values is correct.
NOT here:
View attachment 108786
But ON the battery terminals.
and here:
View attachment 108788
And given that those are puny little Phillips that already look partially boogered up, I would looking at this connection very closely.
Thank you.
Ahh, yes thank you. That is my old PWM charger that I swapped out - I used it for 2 Years and it works great. I still keep it as a backup.
It seems that everyone is saying pretty much the same thing, so as I have already stated, I will be swapping out the wires from 8AWG to 6 AWG. And triple checking all the connections, etc.
Once I pull the counter off the kitchenet and have better access to the system I will do a lot more testing and monitoring, and I will make sure to check the voltages at the terminals like you suggest, for both the charger and the battery
Among many of the concerns people are having is the 1 volt delta between the charger and battery and I appreciate your assistance and theoretical mathematical analysis of the system, though I have to admit, I don't remember a lot of my advanced math... Though I do fully understand the underlying theories and equations. And I do agree with you that there technically is something wrong, especially based on the very solid foundations of the theoretical models you have provided. (But there is a possibility that there is a hidden variable, or factor that is not in the equation... though I think you are very smart and thorough, and I really don't have any idea of what that could be, other then to guestimate and say that the Battery is a "Black Hole" and it is able to absorb energy faster then the current can actually travel through the wires... - I know... laugh right now - hahaha black hole, welling up, etc etc - how can you compare electricity with a garden hose or fluid dynamics - NO ONE uses water through a hose to explain electricity, and any such use of the thickness of a garden hose, or the well that is supplying it to try and explain electricity is ridiculous! lol)
Once I change out the wire I will definitely report back, if this help or fixed the issue, and if not, I'll be willing to looking at other options and reasons, but, as it is right now, my system is running great, the new MPPT with my aggressive settings and the 2 additional solar panel (=6x100w) are giving me more energy then I have every been able to produce and I am using the system to cook with about 750/900 watts for about 4 hours every day!
"As we move into the cooler Fall months, I will continue to monitor and use the system daily, cooking, and even seeing if I can cook and run a small 12v 300 watt heater, and have enough juice. I will monitor the system and I will report back on the progress. I have confidence in my Batteries, and though I may be "shaving years off of them" by using aggressive charging parameters, I am more than sure they will hold up just fine for a very long time, and if not, its not a big deal, they are the cheapest Chinese Packs I could get from China. They could fail for any reason at any moment, and if they die, they die. Based on the safety data on these batteries, there is more of a chance that any other component will fail before the battery cells themselves fail, and if that happens I will tear them apart and harvest them."
Thank you for all your great help and advice. Thanks.