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I'm just a little PO'ed. Return of The Magic Smoke

sorry lost me, as in the 600 volt version of the tristar or some other maker?
It's a Victron 450/100. I was just joking that with the lugs you can get some bigger gauge wire on there. 450V or technically 8 times float voltage is a little crappy when compared to the 600V competition. Morningstar SureSine was one of the hot contenders until I went down the Midnite Rosie path.
 
He thinks I should purchase a smurf colored charge controller. I already told him it isn't color coordinated with my setup. :ROFLMAO:
Even if those two had completely charred from fire you'd still be ahead financially with the eg4s so there's some positives there :)
 
It's a Victron 450/100. I was just joking that with the lugs you can get some bigger gauge wire on there. 450V or technically 8 times float voltage is a little crappy when compared to the 600V competition. Morningstar SureSine was one of the hot contenders until I went down the Midnite Rosie path.
Oh I thought you had come around to the winning side! 🦡 🦡 🦡
ModelTS-MPPT-60-600V-48TS-MPPT-60-600V-48-DB
*Input power can exceed Nominal Operating Power. Controller will limit and provide its rated continuous maximum output current into batteries.
Charge Rating60 amps60 amps
Max. PV Open Circuit Voltage (Voc)600 volts600 volts
Nominal Battery Voltage48V, custom programmable
to 24V, 36V, and 60V
48V, custom programmable
to 24V, 36V, and 60V
Nominal max. Operating Power* – 48 volt battery3200W3200W
Peak efficiency97.9%97.9%
Battery Voltage Range16-72V16-72V
PV Input Operating Voltage Range100V to Voc = 525V100V to Voc = 525V
Self-Consumption1.75 – 2.50W1.75 – 2.50W
Transient Surge Protection4500 Watts/port4500 Watts/port
Voltage Accuracy<=0.1% +/- 100mV<=0.1% +/- 100mV
Operating Temperature Range-40 C to +45C-40 C to +45C
Warranty5 Years5 Years
CE and RoHS compliantYesYes
IEC 62109YesYes
ETL Listed [UL-1741 and Canadian CSA C22.2 No.107.1.01]YesYes
FCC Class B Part 15 CompliantYesYes
Manufactured in a Certified ISO 9001 FacilityYesYes
 
Oh I thought you had come around to the winning side! 🦡 🦡 🦡
ModelTS-MPPT-60-600V-48TS-MPPT-60-600V-48-DB
*Input power can exceed Nominal Operating Power. Controller will limit and provide its rated continuous maximum output current into batteries.
Charge Rating60 amps60 amps
Max. PV Open Circuit Voltage (Voc)600 volts600 volts
Nominal Battery Voltage48V, custom programmable
to 24V, 36V, and 60V
48V, custom programmable
to 24V, 36V, and 60V
Nominal max. Operating Power* – 48 volt battery3200W3200W
Peak efficiency97.9%97.9%
Battery Voltage Range16-72V16-72V
PV Input Operating Voltage Range100V to Voc = 525V100V to Voc = 525V
Self-Consumption1.75 – 2.50W1.75 – 2.50W
Transient Surge Protection4500 Watts/port4500 Watts/port
Voltage Accuracy<=0.1% +/- 100mV<=0.1% +/- 100mV
Operating Temperature Range-40 C to +45C-40 C to +45C
Warranty5 Years5 Years
CE and RoHS compliantYesYes
IEC 62109YesYes
ETL Listed [UL-1741 and Canadian CSA C22.2 No.107.1.01]YesYes
FCC Class B Part 15 CompliantYesYes
Manufactured in a Certified ISO 9001 FacilityYesYes
Next one for me will be either a Hawkes bay 120A or Barcelona 200A.
 
Ok to stop the derail train that I have started, whats the issue with just bypassing that connector and installer a better connector or even a external connection block? if this is the only thing that has popped up while not a happy thing, lets make some lemonade here!

edit: sweet baby Jesus! I just looked at the price for those things (Hawkes bay and Barcelona) I do not want to hear anybody bitching and moaning about Morningstar prices ever again....
 
Ok to stop the derail train that I have started, whats the issue with just bypassing that connector and installer a better connector or even a external connection block? if this is the only thing that has popped up while not a happy thing, lets make some lemonade here!
True could use something like an Anderson SB50 for the PV.
 
If the only issue with the EG4 controller is a crappy terminal block that can be easily bypassed, well, if/when we get our homestead property and I set up a proper system I see it as a minor nuisance but NBD to workaround given the cost savings.

Not saying that EG4 shouldn't look into a better terminal block. Just saying it isn't a showstopper.
 
If the only issue with the EG4 controller is a crappy terminal block that can be easily bypassed, well, if/when we get our homestead property and I set up a proper system I see it as a minor nuisance but NBD to workaround given the cost savings.

Not saying that EG4 shouldn't look into a better terminal block. Just saying it isn't a showstopper.
thats kind of how I look at it. mind you I have morningstars and i understand their price point does not agree with a lot of folks here on the forum. As such I have no dog in the fight, but from the outside looking in, if that's the only issue and they are relatively good to go otherwise, (for the future buyers) I would simply buy a new one and immediately remove that block and replace it with any of several better alternatives. I would go as far to say that if I could get my own crimper in there i would delete it completely and just have a terminal that I riveted or bolted to the outside of the unit in its place.
 
First company to put temperature sensors with alarms/email/text messaging alerts on each connector block wins :)

Hell a big flashing red warning light would be something.

Should be standard on any charge controller over 15 amps.

I have already done this on a few of my inverters and plan on having it on all of them eventually. Too many pokers in the fire atm.

I'm getting to old to keep petting all of my cables to check for overheating.
 
Most victron if you burn pv connectors up they say no warranty blame you.
Right in the victron manuals for most of them.

The gorillia in the room me still says there was no resolution as to why lower inverter position burned up 2x old and replacement.

The top EG4 mppt was operating no problem. 😀 you guys have to reason that out. Or not. Just by-pass it... done. Hahaha
 
Most victron if you burn pv connectors up they say no warranty blame you.
Right in the victron manuals for most of them.

The gorillia in the room me still says there was no resolution as to why lower inverter position burned up 2x old and replacement.

The top EG4 mppt was operating no problem. 😀 you guys have to reason that out. Or not. Just by-pass it... done. Hahaha
Totally get your point. And so far nobody knows why, although as someone who has worked on failure modes post mortem I surmise it could be something as simple as tolerance stacking. That one may simply have a better terminal block, for whatever reason. I know, it is a plate of copper with a set screw to hold the wire in place. But going back to my comment about the ferrule, the plate is ridged and the ferrule is ridged. At that point, slight difference in wire placement in the connector could make the difference between a bad (and hot) connection and a good (and cool) connection. Or as pointed out by others, given the burned point, maybe this one fried because the wire strands got pinched/stressed/broken when the ferrule was crimped on it and that's why it burned up, while the other did not. The lower one could have burned up twice because of two different failure modes, I've seen that before too in other stuff. You need a higher sample than 2 pieces of failed parts to really get a trend of what's going on, otherwise you only have two one-offs that don't tell you anything except those two units had two different problems.
 
Most victron if you burn pv connectors up they say no warranty blame you.
Right in the victron manuals for most of them.

The gorillia in the room me still says there was no resolution as to why lower inverter position burned up 2x old and replacement.

The top EG4 mppt was operating no problem. 😀 you guys have to reason that out. Or not. Just by-pass it... done. Hahaha
I think its a heat over time thing between the upper and lower. whatever is feeding the bottom is hotter longer, long enough that it finally dies. like I said in an earlier post, it could be something as simple as one set of panels running cooler due to but not limited to airflow over the panels and outputting more energy as a result. or it could be one of the controllers voltage sensor is slightly off compared to the others so its throttling back earlier. hence try moving the top controller into the bottom slot and see if it does the same. that would indicate a PV field issue or wiring issue between the panels and the controller.
 
Just wire nut your connections and call it good.
I thought they were the most bizarre things when I first arrived in the USA but now I love them, a great connection method if done properly.
I'm still thinking they had a reel of shit wire that got used up in these things.
 
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Sometimes the right amount of money can solve things.... the old basic statement - saying, "spend big cry once."
It only hurts when a person does that and still has problems or the bar of spending is increased x amount more afterwords.....

My question when OP brings his new dual SRNE 10k ASP aio inverters online will the EG4 mppt be retired? He will have a total of 4 mppt built in with the dual SRNE 10k ASP. If the pv connector on the SRNE catch on fire with that string ...... what then? By pass them too? 😀 hmmmm....
 
True could use something like an Anderson SB50 for the PV.
What’s the voltage rating of those? I thought it was much lower, more suited for battery voltages than PV voltages.

Edit I did my own googling, 600v, not bad and you get to use your crimping tool too.
 
Totally get your point. And so far nobody knows why, although as someone who has worked on failure modes post mortem I surmise it could be something as simple as tolerance stacking. That one may simply have a better terminal block, for whatever reason. I know, it is a plate of copper with a set screw to hold the wire in place. But going back to my comment about the ferrule, the plate is ridged and the ferrule is ridged. At that point, slight difference in wire placement in the connector could make the difference between a bad (and hot) connection and a good (and cool) connection.

This could be a cause, it definitely cuts down on the surface contact area. Basically, wire size is marginal to begin with, then the cross sectional area of contact is reduced possibly as high as 75% with the ridges on both pieces.

I did just take these closeup photos and did separate the wire and ferrule from the copper bar.

Connector1.jpgConnector 3.jpgConnector 4.jpg

The left side of the last photo is where the wire burned off.

It definitely appears to be the hottest point of the connection. The black char I believe was the melted insulation that ran down the connection and burned.

Looking at the color of these photos, the bar almost appears to be brass with a copper coating? I don't think the bar is pure copper but possibly contains some other metals in the mix.


Or as pointed out by others, given the burned point, maybe this one fried because the wire strands got pinched/stressed/broken when the ferrule was crimped on it and that's why it burned up, while the other did not. The lower one could have burned up twice because of two different failure modes, I've seen that before too in other stuff. You need a higher sample than 2 pieces of failed parts to really get a trend of what's going on, otherwise you only have two one-offs that don't tell you anything except those two units had two different problems.
I agree, 2 failures is not a large enough sample size.

Replacement should be here next week, I will leave the connectors bypassed from this point on and leave the 10AWG all the way to the PCB from the IMO.
 
Sometimes the right amount of money can solve things.... the old basic statement - saying, "spend big cry once."
It only hurts when a person does that and still has problems or the bar of spending is increased x amount more afterwords.....

My question when OP brings his new dual SRNE 10k ASP aio inverters online will the EG4 mppt be retired? He will have a total of 4 mppt built in with the dual SRNE 10k ASP. If the pv connector on the SRNE catch on fire with that string ...... what then? By pass them too? 😀 hmmmm....
Different system, the SRNE are for my shop solar system.

The pair of EG4 MPPT's will remain in the house. I have 4 MPPT's in the pair LV6548's I'm not currently using but may add more PV by the house and utilize those. I have the mount and extra panels.
 
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