Cruisers Forum
 


Join CruisersForum Today

Reply
 
Thread Tools Rate Thread Display Modes
Old 13-01-2016, 15:42   #1
Registered User

Join Date: Nov 2005
Location: Full Time Cruising
Boat: 1990 Morgan 41 Classic
Posts: 54
Xantrex Marine 20 very hot cable

When I put my Xantrex Marine 20 in charge mode charging my 6 golf cart batteries the cable that goes from the charger to the big fuse between it and the batteries gets very hot near the fuse and emits a smell. The fuse also gets very hot.

I replaced the fuse but that did not help. Any advice would be helpful trying to diagnose this.

It does charge through the entire cycle.

Thank you
__________________

__________________
laser is offline   Reply With Quote
Old 13-01-2016, 15:58   #2
Senior Cruiser
 
colemj's Avatar

Cruisers Forum Supporter

Join Date: Oct 2005
Location: Presently on US East Coast
Boat: Manta 40 "Reach"
Posts: 10,049
Images: 12
Re: Xantrex Marine 20 very hot cable

There is resistance somewhere. Either the cable is too small, the cable fittings are loose, there is corrosion on the fittings or inside the cable, the fuse holder has loose or corroded contacts, etc.

Mark
__________________

__________________
www.svreach.com

You do not need a parachute to skydive. You only need a parachute to skydive twice.
colemj is offline   Reply With Quote
Old 13-01-2016, 16:00   #3
Long Range Cruiser
 
MarkJ's Avatar

Cruisers Forum Supporter

Join Date: Dec 2007
Location: Australian living on "Sea Life" currently in England.
Boat: Beneteau 393 "Sea Life"
Posts: 12,828
Images: 25
Re: Xantrex Marine 20 very hot cable

The fuse needs to be quite large.

And as the other Mark said: check the connections.
__________________
Notes on a Circumnavigation.
OurLifeAtSea.com

Somalia Pirates and our Convoy
MarkJ is offline   Reply With Quote
Old 13-01-2016, 16:11   #4
Senior Cruiser
 
colemj's Avatar

Cruisers Forum Supporter

Join Date: Oct 2005
Location: Presently on US East Coast
Boat: Manta 40 "Reach"
Posts: 10,049
Images: 12
Re: Xantrex Marine 20 very hot cable

I thought you were the other Mark?

Mark
__________________
www.svreach.com

You do not need a parachute to skydive. You only need a parachute to skydive twice.
colemj is offline   Reply With Quote
Old 13-01-2016, 16:35   #5
Registered User

Join Date: Nov 2005
Location: Full Time Cruising
Boat: 1990 Morgan 41 Classic
Posts: 54
Re: Xantrex Marine 20 very hot cable

Thanks for the quick replies. The fuse is correct as its the one that has been there for years. I took a look at the connector on the cable and the crimp may have vibrated loose as you suggested. I have a new lug...if thats what you call it...and I will replace the one that may be loose tomorrow night after I get into a marina and see if that fixes it.
__________________
laser is offline   Reply With Quote
Old 13-01-2016, 17:01   #6
Long Range Cruiser
 
MarkJ's Avatar

Cruisers Forum Supporter

Join Date: Dec 2007
Location: Australian living on "Sea Life" currently in England.
Boat: Beneteau 393 "Sea Life"
Posts: 12,828
Images: 25
Re: Xantrex Marine 20 very hot cable

Yes, if its been fine for 3 years and now hot then it "must" be a connection.

Mark
__________________
MarkJ is offline   Reply With Quote
Old 13-01-2016, 17:57   #7
Senior Cruiser
 
Jim Cate's Avatar

Cruisers Forum Supporter

Join Date: May 2008
Location: cruising SW Pacific
Boat: Jon Sayer 1-off 46 ft fract rig sloop strip plank in W Red Cedar
Posts: 11,461
Re: Xantrex Marine 20 very hot cable

Mark my words, you Marks are just marking time until you finally make your marks in the world...

Jim
__________________
Jim and Ann s/v Insatiable II , lying Port Cygnet, Tasmania once again
Jim Cate is online now   Reply With Quote
Old 13-01-2016, 18:42   #8
Long Range Cruiser
 
MarkJ's Avatar

Cruisers Forum Supporter

Join Date: Dec 2007
Location: Australian living on "Sea Life" currently in England.
Boat: Beneteau 393 "Sea Life"
Posts: 12,828
Images: 25
Re: Xantrex Marine 20 very hot cable

Quote:
Originally Posted by Jim Cate View Post
Mark my words, you Marks are just marking time until you finally make your marks in the world...

Jim

I am sure Ann has some varnishing for you to do, Jim.



And I am retired so finding marks in the world is as good a vocation as any... Maybe finding Sarah's would be more fun...
__________________
MarkJ is offline   Reply With Quote
Old 13-01-2016, 19:38   #9
Registered User
 
Reefmagnet's Avatar

Join Date: May 2008
Location: puɐןsuǝǝnb 'ʎɐʞɔɐɯ
Boat: Nantucket Island 33
Posts: 2,737
Re: Xantrex Marine 20 very hot cable

Put a voltmeter across the fuse and connections (as in the leads either side of the fuse / connection) in turn and write down the voltage. Compare the readings. Normally you would only have millivolt readings, so a higher reading could indicate a problem. Higher readings mean higher resistance and more heating.

If all the above checks seem ok (which I doubt they will), check your cable by reading the voltage at the charger terminals and then at the battery terminals. A differential of a couple of volts or so indicates undersized leads.
__________________
Reefmagnet is offline   Reply With Quote
Old 14-01-2016, 06:03   #10
Senior Cruiser
 
colemj's Avatar

Cruisers Forum Supporter

Join Date: Oct 2005
Location: Presently on US East Coast
Boat: Manta 40 "Reach"
Posts: 10,049
Images: 12
Re: Xantrex Marine 20 very hot cable

Quote:
Originally Posted by MarkJ View Post
I am sure Ann has some varnishing for you to do, Jim.

Sounds to me like he has been doing too much varnishing...

Mark
__________________
www.svreach.com

You do not need a parachute to skydive. You only need a parachute to skydive twice.
colemj is offline   Reply With Quote
Old 14-01-2016, 10:10   #11
Marine Service Provider

Join Date: Sep 2011
Location: California
Boat: Alerion Express 38 Yawl
Posts: 269
Re: Xantrex Marine 20 very hot cable

At the risk of redirectly the discussion back to the hot cable, the location of the heat is the location of the problem. For example, if one side of the fuse block is hotter than the other, look on the hot side. I suspect that the crimp on the cable terminal has either some corrosion in it, or it was never quite crimped correctly, and there is resistance.

It's doubtful that the problem is under the insulation of the wire, unless the boat environment is really wet. It's either the terminal crimping or it's the security of the terminal on the fuse block.

Since I didn't have one of the big "bolt cutter" style tools on board, I used the old bolt-together Nicopress tool for most of my big battery cables with very good results.

See WEST MARINE Hand Swaging Tools | West Marine

I know this isn't entirely to code but for all terminals that I used, I could find a die that put great pressure on the wire. I also used the Ancor adhesive-lined shrink tubing for strain relief and insulation.

Chuck
__________________
Chuck Hawley is offline   Reply With Quote
Old 14-01-2016, 12:08   #12
Senior Cruiser

Cruisers Forum Supporter

Join Date: Apr 2015
Location: Lakeland, Florida
Boat: Irwin Citation 34
Posts: 131
Re: Xantrex Marine 20 very hot cable

I suggest also applying NOALOX to the bare wire before crimping the new lug. NOALOX is a commercial lubricant and sealer to keep out moisture in the crimp.
Available at any electrical supply house.
__________________
Captndave1 is offline   Reply With Quote
Old 14-01-2016, 13:30   #13
Registered User

Join Date: Nov 2005
Location: Full Time Cruising
Boat: 1990 Morgan 41 Classic
Posts: 54
Re: Xantrex Marine 20 very hot cable

Stop Marking up my thread? :-)

Thank you for all the advice. I found the connector on the end of the cable to the Xanrex was loose and a little oxidized. I cut off the end of the cable to have fresh copper and installed a new connector...fortunately vice grips and a bolt cutter made for a good crimp.

The cable is now down to its old slightly warm while charging. All other connections were clean although i sanded them off as well.

Now on to the next project.

All Marks may now resume the hijack.
__________________
laser is offline   Reply With Quote
Old 14-01-2016, 17:11   #14
Registered User
 
Boatyarddog's Avatar

Join Date: Nov 2014
Location: Olympia, wa.
Boat: Mariner Ketch 32- 1979- hull 202
Posts: 632
Re: Xantrex Marine 20 very hot cable

Quote:
Originally Posted by MarkJ View Post
I am sure Ann has some varnishing for you to do, Jim.







And I am retired so finding marks in the world is as good a vocation as any... Maybe finding Sarah's would be more fun...

Much more fun is researching Shiraz in ones spare time.


Sent from SV Cloud Duster
__________________
Boatyarddog is offline   Reply With Quote
Old 14-01-2016, 17:16   #15
Registered User
 
Boatyarddog's Avatar

Join Date: Nov 2014
Location: Olympia, wa.
Boat: Mariner Ketch 32- 1979- hull 202
Posts: 632
Re: Xantrex Marine 20 very hot cable

Quote:
Originally Posted by laser View Post
Stop Marking up my thread? :-)

Thank you for all the advice. I found the connector on the end of the cable to the Xanrex was loose and a little oxidized. I cut off the end of the cable to have fresh copper and installed a new connector...fortunately vice grips and a bolt cutter made for a good crimp.

The cable is now down to its old slightly warm while charging. All other connections were clean although i sanded them off as well.

Now on to the next project.

All Marks may now resume the hijack.

You should check this tool out for crimping, works great for me.
And I'm sure it's a Ton better that Vgrips or a bolt cutter.
https://www.amazon.com/s/ref=nb_sb_n...mped+hydraluic


Sent from SV Cloud Duster
__________________

__________________
Boatyarddog is offline   Reply With Quote
Reply

Tags
marine

Thread Tools
Display Modes Rate This Thread
Rate This Thread:

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
HOT HOT HOT! running AC on Honda generator sailorboy1 Plumbing Systems and Fixtures 12 09-07-2013 18:07
One Very, Very, Very Lucky Sailor nigel1 Off Topic Forum 13 09-11-2011 08:04
So You've Been Very, Very Good . . . Your Boss . . . otherthan General Sailing Forum 6 27-12-2010 21:11
Very Small, Very Efficient Ice Cube Maker Wanted for Sundowners Fuss Plumbing Systems and Fixtures 21 20-07-2010 07:09
Ohhhhh Hot! Hot! Hot! knottybuoyz Marine Electronics 6 01-06-2007 08:43



Copyright 2002- Social Knowledge, LLC All Rights Reserved.

All times are GMT -7. The time now is 00:26.


Google+
Powered by vBulletin® Version 3.8.8 Beta 1
Copyright ©2000 - 2017, vBulletin Solutions, Inc.
Social Knowledge Networks
Powered by vBulletin® Version 3.8.8 Beta 1
Copyright ©2000 - 2017, vBulletin Solutions, Inc.

ShowCase vBulletin Plugins by Drive Thru Online, Inc.