Robbie and Dave Thank you both!!!!!!

Thanks Robbie and Dave from the Alt-E forum!!!!!

http://www.altestore.com/forums/Renewable-Energy/Technical/Showing-voltage-over-disconnect-breaker-/index.php/topic,2097.0.html


You have lifted my spirits and have both been a collective voice that has helped me to continue with my dream. I appreciate your support so much, at a time when I needed it the most!!!! I'm back on the project with determination in my heart thanks to both of you!!!

This morning I flipped the 70 amp breaker to the battery bank and I have juice to the Outback Flexmaxx 60 Solar Controller...it sees the battery bank, it's voltage, and the fact that I don't have the solar panels snapped into the combiner box yet. I have "lift off", Houston we don't have a problem yet, "Godspeed John Glenn" !!!!


Info on my wiring of breakers and photos of the box below:

DC Quick Disconnect Breaker 250 Amp rating:

• The 250 amp breaker is wired with the Positive Inverter Cable is on top and the Battery Positive Cable on the bottom of the breaker. There is also a connection between the bottom of the 250 amp breaker and the bottom of the 70 amp breaker for the PV output disconnect.

PV Output Disconnect 70 Amp breaker:

• The top part of the 70 amp breaker runs to the Battery positive in the Solar Controller. Bottom of the breaker runs to the hook up with the positive Battery Bank wire on the bottom of the 250 breaker.
  

PV + Input Disconnect 60 Amp breaker:

• The 60amp breaker (top) runs to the DC Ground Fault Breaker top. The bottom part of the breaker holds the PV Positive in connection coming directly from the array from outside.
  

Ground Fault Breaker:

• The Ground fault breaker I have a negative wire coming out of the .5amp section (bottom of the breaker) and a ground (running from the top) I also have a connection from the GFI top 60 amp breaker running to the other 60 amp breaker top. The bottom part of the GFI runs to the PV positive that goes directly to the Solar Controller.

• The back of the DC box show the Negative battery connection running to the inside of the post at the DC negative bus and the Negative Battery lead from the Solar Controller is running to the second post on the DC Negative Bus along with the negative wire from the bottom of the .5amp ground fault breaker.

• I also have the ground wire that runs from the array with the PV positive and PV negative wires, attached to a 8' ground rod and tied into the box at the ground bus. The solar controller, the dc box itself and the inverter all have a copper ground that ties into the system.

• I've also included a photo with the cover on.

I used the breaker instructions for wiring the box using the MNDC Installation Instructions since I wasn't too happy with the clarity of the Flexware 500 guide. The User guide might be great for a master electrician but I am not one nor do I play one on TV.

Here are some shots of my battery bank.

4 105 amp hour batteries wired in parallel and the inverter.
I'm not happy with the inverter connection I had to use a jumper cable battery (2 gauge) and try to tin the wires with a small butane torch.

Inside the Solar controller box...that seemed to be pretty straight forward with wiring.

And last is the And last, is the Combiner Box, this seemed fairly easy to wire also..slots for PV Positive and Negative, ground and the lightning arrestor wired in.