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Reliable electrical connections for outdoor generator
Kwschumm,
You're on the right track. It sounds to me as though you have a good handle on the problem, as well as the solution.
I'm not sure that it's necessary to go with marine grade components, but doing so will provide you with many good years of service. Cost is the biggest factor here.
Levitron is a very good make. They provide electrical components and devices for thousands of applications. I've have nothing but good things to say about Levitron's top-line products.
Like every manufacturer, Levitron offers different grades of products. They make products that meet home-building code requirements, as well as commercial code devices. The "Professional" line is high quality stuff.
If I were in your shoes, I'd make a visit to your local electrical jobber/distributor........the place the electricians go when they need supplies. It will be a wholesale outfit. They offer all grades of supplies, and can help you choose the best components and tools for your project.
Joel
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Reliable electrical connections for outdoor generator
Kwschumm,
If your problems relate only to the low voltage control circuits, you can probably take care of this problem with very little expense.
Purchase yourself some good low voltage switches....the ones with copper plated terminals. Shy away from the .99 cent jobbies. After getting yourself some good low voltage switches, hard solder all of the connections, rather than using those cheap, crimped-on terminal ends.
Slip a piece of properly sized shrink tubing over each wire end, prior to completing the solder joints. You can then use a heat gun, or even a wood match to shrink the tubing down to complete a weather-tight seal.
Some helpful hints........
Use rosin core solder, designed for electrical work. Acid core solders will attack and destroy the electrical connections.
Use a good solder paste designed for electrical work. This will help your solder flow properly, making for a very neat, clean, and professional connection.
Clean all terminal ends with a small steel brush (Dremel tool wire brush works great) prior to connecting the wires to the switches. This will help the solder paste do its job, as well as provide a clean surface for the solder to attach to.
Switch terminals often oxidize. You can purchase a spray cleaner to spray inside the switch to clean those terminals. It won't hurt the switch, nor harm the plastic housing. Look for a product called "LPS PSC". This is a Plastic-Safe-Cleaner, designed for use on small electrical switches, printed circuit boards, kids toys, etc.
See the link below.
You'll never have to fix this stuff again.
Joel
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