Solar Boost 200E Stopped Working

[MarkJ]

Originally Posted by Sonosailor

Query: Why do the manufacturers all push you to use #10 wire or larger, but make screw connections that can only hold #14 or smaller?

Yes. Crazy.

[gunnado]

I hope you have a multimeter with a dc clamp amp measurement. Use after you've checked all terminations.

Use your multimeter under full load or fault conditions at the controller,
Battery voltage is 12-14.4v?
Solar pv is 12-48v?

If these are correct remove solar pv wires and short together, then use your clamp meter to measure the amps. Should be around 5-16 amps in dead short circuit, depending on configuration?

I would do this test together and separate on your panels as you are saying one works. Maybe a solar panel is going open circuit?

Write down the measurements and if they are in range return controller to manufacturer for replacement.



Sent from my iPhone using Cruisers Sailing Forum

[gunnado]

Just read the full post, looks like you have solved it?

I have no idea why the screw terminals are always to small!!!


Sent from my iPhone using Cruisers Sailing Forum

[Sonosailor]

I did solve it. Sorry for not maintaining the postings, but I went to sea, and thought I had parked the thread correctly. Here is my final solution:

I removed all wires from the controller, labelled them, snipped them and crimped on proper eyelets and shrinkwrap. I installed a sweet little terminal strip to allow combining the leads where appropriate and necessary. I took new, properly assembled wires from the terminal strip into the controller. I also ensured all contacts, wires, etc were properly cleaned and coated with a thin layer of dielectric grease.

Now, I can see the connections and combinations, test and troubleshoot easier next time, and the connections to the controller are manageable. We just have to learn to do it right the first time, and get the hell away from poor crimpers and butt connections. Oh, and use dielectric grease or vaseline - even on a cracker. ;-)

As always, thanks for everybody's help.