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60kW Whole House Powerwall build
#31
(10-16-2019, 02:49 PM)Korishan Wrote:
(10-16-2019, 02:13 PM)LPG Wrote: Cleaning is my next step. Before removing the shunt to see if there is a difference in temps.

This shunt should be able to handle the power I'm putting through it, it's rated at 1000A and at the absolute max (which isn't very often) I'm putting 300A through it.

Sounds good.

It's possible the shunt could be hot from the connection, then. Which is definitely more desirable than the alternatives. It's cheaper Wink
At 300A, that thing should be cold to the touch. So yeah, I would guess the connection is causing the issue.

Not sure if you saw Petes video when he checked his connections with his Flir, but he found a loose bolt using it. Even by touching, he couldn't tell much of a difference between that connection and the others. But the Flir caught it clearly. I think he got about a 1/4 turn when tightening. So it doesn't take much to cause heat build up through resistance at those amp levels

Do you have a link to the video?
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#32
(10-16-2019, 03:30 PM)LPG Wrote:
(10-16-2019, 02:49 PM)Korishan Wrote: Not sure if you saw Petes video when he checked his connections with his Flir, but he found a loose bolt using it. Even by touching, he couldn't tell much of a difference between that connection and the others. But the Flir caught it clearly. I think he got about a 1/4 turn when tightening. So it doesn't take much to cause heat build up through resistance at those amp levels

Do you have a link to the video?

I was gonna say no, but I figured I'd scrub his videos and find it for ya:
https://youtu.be/gceZLsR5XSo?t=365

Timestamp location goes directly to that part. The camera detected 76C on the one connection, and only 50C on the other ones.
(Even tho he says 74, the reading said 76 at one spot)
He states in this video about the crimp not being tight enough. I think there was another video where it was the bolt needed tightening. But still, it was a loose connection "on" the lug itself, whether it was wire or bolt. That's a lotta heat generation from loose connection.
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#33
(10-16-2019, 07:23 PM)Korishan Wrote:
(10-16-2019, 03:30 PM)LPG Wrote:
(10-16-2019, 02:49 PM)Korishan Wrote: Not sure if you saw Petes video when he checked his connections with his Flir, but he found a loose bolt using it. Even by touching, he couldn't tell much of a difference between that connection and the others. But the Flir caught it clearly. I think he got about a 1/4 turn when tightening. So it doesn't take much to cause heat build up through resistance at those amp levels

Do you have a link to the video?

I was gonna say no, but I figured I'd scrub his videos and find it for ya:
https://youtu.be/gceZLsR5XSo?t=365

Timestamp location goes directly to that part. The camera detected 76C on the one connection, and only 50C on the other ones.
(Even tho he says 74, the reading said 76 at one spot)
He states in this video about the crimp not being tight enough. I think there was another video where it was the bolt needed tightening. But still, it was a loose connection "on" the lug itself, whether it was wire or bolt. That's a lotta heat generation from loose connection.


Thanks for the link. l put the house on bypass and removed the connection to clean it. I did find the bolt wasn't tight enough to my liking so that could have been it, also while I was at it I cleaned all the black off the lug and left it at bare copper, cleaned both surfaces with rubbing alcohol and tightened them backup. While I was at it I also checked my busbar connections and made them a bit tighter since most of the negatives seemed a bit loose.

Here are the results:



The connection to the sensor is now cold as it should be BUT I have found another issue (which funny enough is the same as Pete mentioned in that video). The lug crimp seems to not have been done to par as it is now the hot spot. That's what I get for using the BMS cables the way they came, I'll have to cut off the current lug and re-crimp them properly.
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#34
Now you know what to look for Smile

Glad you found out what was going on. Sometimes it takes several steps to get to the root of the problem. It's just a pita to have to keep disassembling/reassembling to find the problem Tongue
But progress is made, and your system will be much more efficient because of it.
Proceed with caution. Knowledge is Power! Literally! Cool 
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