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Old 13-09-2014, 10:15   #16
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Join Date: Sep 2011
Location: On a boat
Boat: Cabo Rico 38
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Re: Solar Charge Controller Confusion

Originally Posted by Mike Sibley View Post
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.

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Old 03-10-2014, 09:25   #17
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Location: St. Augustine,fl.
Boat: charley morgan-38
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Re: Solar Charge Controller Confusion

enjoyed reading this thread,,im in the process of refitting our Morgan, can anyone advise what brand of solar panel you would recommend, along the 150-200 watt range thanks,

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