Originally Posted by Mike Sibley
Unfortunately, the set screw is very small and engages only the very tip of the wire, allowing the wire to fall out in response to any movement. This creates a hazard of a short circuit and a resulting fire. I found a way to solve the problem (with additional work and expense), but I was disappointed that the unit wasn't better designed.
I have the same issue with my genasun controllers. What is recommended is to sandwich a run of 8 gauge (or whatever is appropriate) between the solar panels
and the smaller wire necessary to get inserted into the controller... you only need an inch or so of the appropriate wire size so the voltage drop is almost non-existent.
Just be sure to make a really good connection between the two wires. Others may be able to give you a better solution but I connected the larger wires from the solar panels
through an inline fuse and then ran the left-over inline fuse wire directly to the controller. For the ground wire, I just connected using a butt connector but you may be better off using a block.