Originally Posted by Sandero
I bought a new inverter... Xantrax ProWatt 1000.
When I removed the old one... I found sever corrosion on the neg 12v terminal. 12 pos was fine. The neg had over heated.. and melted the plastic house of the connector. Obviously this WAS the problem.
The inside of the unit looked fine... and it does work when the voltage demand is not very high... obviously the heavy 12v neg was way under performing. I don't know if a spare connector body is available. I could fabricate something. But it's hardly worth it.. a rainy day project.
The question in my mind is what's up with the 12v neg? I had a problem with the 110v neg wiring as well... with overheating perhaps starting from corrosion.
Why the neg? This makes me think there is some fault in the wiring perhaps. And if there is... I haven't a clue as to how to find it short of completely rewiring both a 110 and the 12v systems or at least checking every single wire. No signs of corrosion on any small wiring.
Pictures would help. A 1000W inverter draws about 100A max. Xantrex recommends AWG 0 wire which requires special compression
tools to make a proper crimp. High current
connections that overheat due to lack of sufficient compression
or insufficient bolt pressure can look a lot like corrosion. A common scenario goes like this:
1) Ring lug or compression terminal isn't tight enough or is too small for the current.
2) Connection warms up under load.
3) Bolt expands slightly relaxing the pressure on the ring lug.
4) Less pressure causes more heating
5) Process runs away until the connection is red hot.
When the metal gets red hot it oxidizes and then when it cools is easily mistaken for corrosion.
An infrared thermometer is a good tool to check connections periodically for unusual heating
. The infrared sensor can quickly and safely check temperature from a distance. It's a good maintenance
procedure to check for changes in temperature of high current connections every month.
Also, are there any batteries close to this terminal? If so, gas escaping from the battery
can cause corrosion.