Wire direct and bypass the connection at this point. The connection is very dangerous and I will be bypassing the connections for both PV wires. The battery cable connections might have enough contact area and mass to dissipate any heat.
I can't remember the name of the process but that wire end looks "crimp welded", I don't know the proper terminology but it appears to be compressed/fused and I'd say that may be the cause, where the rigid part of the wire meets the flexible part may have flexed and broken a couple strands causing it to not be able to handle the current. I'd guess the gauge of the wire should be thicker to accommodate some loss of strands, or ideally use bootlace ferrules instead of the "crimp" method they appear to have used, bootlace ferrules will allow a slight movement of individual strands during assembly of the unit
Come over to the DIY Solar Forum and read up on ferrules in the discussions. I had ferrules on my side of the connection and still have ferrules on the other charge controller but many blame the manufacturer installed ferrule or any ferrule for a failure. I'm still on the fence, I prefer a ferrule.
My two EG4 charge controllers just got delivered today. Now I’m concerned!
Wire direct and bypass the connection at this point. The connection is very dangerous and I will be bypassing the connections for both PV wires. The battery cable connections might have enough contact area and mass to dissipate any heat.
I can't remember the name of the process but that wire end looks "crimp welded", I don't know the proper terminology but it appears to be compressed/fused and I'd say that may be the cause, where the rigid part of the wire meets the flexible part may have flexed and broken a couple strands causing it to not be able to handle the current. I'd guess the gauge of the wire should be thicker to accommodate some loss of strands, or ideally use bootlace ferrules instead of the "crimp" method they appear to have used, bootlace ferrules will allow a slight movement of individual strands during assembly of the unit
Come over to the DIY Solar Forum and read up on ferrules in the discussions. I had ferrules on my side of the connection and still have ferrules on the other charge controller but many blame the manufacturer installed ferrule or any ferrule for a failure. I'm still on the fence, I prefer a ferrule.
This make Victron Spring clamps look skoocum AF.
I don't know about that, the photos shown on the DIY Solar Forum where Victron spring clamps failed indicate the Victron might be worse.
@@doczwy8143 installation error vs manufacturing error. I’d much rather blame myself for screwing up vs set up for failure by the manufacturer.