Webbie

A big thank you to @P1000 and @BritishRacingGreen for taking the time to actually look at the data logs of my batteries.
I contacted Pylontech China directly paraphrasing what the both of you mentioned and this was their response:
"A few days ago, in the communication with Segensolar, there were two cases where this situation occurred. After re-checking the log, I think that the cells have been unbalanced before the overcharge data occurs. So I changed the warranty judgment and replaced the new batteries under warranty for the customer.   We will continue to pay attention to similar cases and provide customers with warranty services."   I was then offered 2 X US2000C batteries as replacements but decided to take a credit note instead.   I think many people are correct in that to get any company in South Africa to honour a warranty is next to impossible BUT not impossible!   They rely on customers not really understanding the technology and baffling them with multipage data logs in the hope that you just give up.   Thank god for this forum and the people on it who willingly help out strangers, you literally saved me a small fortune!   It is however a long, long process (nearly 6 months!) but worth exploring every avenue before throwing in the towel.   I hope this might help some other members in their warranty claims as there does seem to be gremlins in those US2000 series batteries...   Thanks again!

Thank you @RichardvdS for letting everyone know what had gone wrong in the end.

Hmm i don't share your opinion.
10 x 275w panels at 38.6VOC = 2750w / aprox 35vmp = 78.57 Amps. That's a hell of a lot of amps going down the PV lines to me. I would really hope these lines are super large in size and super short in length.
Do what @jumper has said and make your system groups of 3 panels in series.
3 in series x 38.6V = 115.8V VOC so even with 10% extra on a really cold sunny day there is plenty of margin before you reach the 145V the inverter supports.
4 in parallel x 7.85 amps = 31.4 Amps Much safer loads for the PV cables to handle.
So the 3 in series combined with 4 in parallel is by far the safest option for you.
Far safer to have higher voltages and lower amps but make sure you stay well under the 145VOC the inverter can handle. Just under is not good enough because at colder temps to the 25 Deg C they rate the panels at the VOC will increase. In my case i get 10% extra voltage at 3 deg c compared to the 25 deg so it is something you need to account for or you learn the hard way like i did when in the middle of winter the inverter shuts down due to the excessive solar voltage coming in.

Let me tell you the Pylontech 10-Year warranty means nothing , not worth the paper its printed on. And as for the protection they rave about on page 3 of the manual point 2&9 means nothing because when the Battery BMS boards fail and it goes over volt as high as 55 volts  that 1.5 volts above the rated voltage they say you abused the battery and it was at 55 volts for 5 min, they also say if you go over 37 amps you will loose your warranty yet the manual says up to 74 amps? mine has never been over 37 amps but that's the story they will give you,  and then send you a bill for $300 to replace the BMS boards , components you have no control over, 
My questions are where are these Protections?
2) NEW: Dual active protection on BMS level.
9 )Battery management system (BMS)has protection functions including over-discharge, over-charge, over-current and high/low temperature
And now the latset stock they have, are having BMS failure due to inferior chip-sets they had had to use because of COVID , and the boards are failing, if they dont fail they may be able to put new firmware on and not sure how they operate after that?
 
I would think twice before buying another Pylontech product.

I first started off with a Must 5kva inverter, 9.6kva batteries (Gel) and 1.5kw worth of panels with no grid connection at all. 
The inverter didn't have to worry about half your gear and worked mostly for the loads we put onto it. The problem comes when your not able to control the loads. Ie fridge, freezer kicking in.
With what you are listing i would think you will probably be running into problems. I.e pool pump running for 4 hours, dishwasher requiring 3 hours it becomes very hard to balance your energy load. We had a 50L hot water system that when i turned it on, if the pump was running and the fridge turned on then it would overload the inverter. of course this depends on the appliances as my new 600l fridge draws 1/4 the power of my old 430L fridge did.
You could use this as a starting spot but things like the inverter which you can parallel to increase the power might have gone out of production and you can't parallel units that are not the same, when your ready to upgrade.
If i had that lot of gear and wanted that setup then i would start by making a separate power circuit which is just the solar and start putting the things that run all the time onto that circuit. This would reduce your energy costs and give you a good starting with what you can and can't do with solar off grid. to start with off grid was all about load balancing and having to choose what you required as a higher priority. Also the difference between summer and winter in terms of power is big. 4 less hours of sunlight = more power running things from the batteries required.
Keep a diary for a week and list what is running at what time of the day. I would recommend buying a cheap load meter which you can move from device to device and see what loads they actually do require. See what start up load and running loads each device uses and then work your system based on what you actually have already in use and the way you are currently using them. it might be a pain for a week keeping track of everything but the better you know that the better you can prepare. I.e if you have 1 person running the microwave, 1 person having a shower and 1 person using the hairdrier even if it is for only a few seconds of cross over could be the difference between inverter handling the load vs tripping from overload. Things like the pool pump and dishwasher i would only run during sunlight periods. Overcast or winter days though PV input may not be as high as you would like so the more your running on those days the less recharge is going into the batteries. End of the day it is well worth the $20 to buy the meter and run around for a week seeing what your loads really are and when you doing it all. Better the mathematics going in the better the mathematics will be coming out.
It may just be better for you to spend more money on a bigger solar array and change to using all the power hungry gear during the day when the solar is free power for you and only buying the small loads for overnight. I know a few people who wanted to go off grid and i advised them to go this way instead just to see what completely off grid feels like before they have the expense of batteries and rewiring. For some the found the power bills dropped enough that they no longer cared about going off grid. Others decided working to a sun's up so i can do stuff rule was simply to hard so continue to pay the big bills. 
There is no easy one size fits all so please do the math's. Putting a good PV system on the roof now means you already have panels ready for when you switch to off grid later, so it's not a one way or the other sort of idea.

If you are running 3 phase equipment then a problem can occur, but most don't run that sort of equipment and really only need a single phase.
Most Grid suppliers will tell a installer which phase they would prefer the inverter to be installed on so they can balance the phases. With 3 phase and some equipment a difference of a small number of volts between the phases can cause havoc hence the reason why they choose where it goes. Some companies are allowed to test the phases and then add to the lowest phase but this will depend on your area.
Most simply convert there whole house to run on a single phase (the same phase as given above) as it's a lot easier and never have to worry about balance issues and makes things simpler for all parties envoled.

Just wanted to let you all know that i have reported Pylontech to the ACCC over this matter. Though they won't help my situation, i do think if anyone who has had the same warranty denied by pylontech reports it to the ACCC, then maybe someone else might actually get the warranty they paid for from Pylontech. The more people who do report them the better the odds of the ACCC taking action.
Here is my reasoning.
1) If the battery BMS is passive only which Pylontech have informed me, then the battery protection is only for a very short time (as my logs show a 4 second window between entries in some cases) and not a true disconnect as i would expect, then a lot of the errors they claim void the warranty would not have occurred at all. All the extra over voltage entries occurring due to this, would lessen my entries 30 fold if i didn't make changes to the inverter and just restarted the batteries no knowing what had happened.
2)If the battery does not disconnect how is a end user to know when a over voltage event has ever happened? Is the user required to sit in front of the unit staring at the little red error LED waiting for it to go on for the 3 seconds that the error is happening over before the BMS resets and things return to normal status?
3) Pylontech does not make the Batteryview software publicly available for people to check the errors on the batteries to find any faults to correct.
4) having a passive BMS that does not disconnect the battery is misleading and unsafe. I and I'm sure plenty of others purchased these batteries because they thought the BMS would protect the battery against most of the potential problems that do damage to the cells.
5) Saying you have to have an approved inverter when they don't publish what inverters they do support up front. And if they did and they change what brands they support would your support inverter at time of purchase be claimed as a unsupported inverter years later when you try to make a claim?
Good luck @OzzyMozzy

Just wanted to let you all know that i have reported Pylontech to the ACCC over this matter. Though they won't help my situation, i do think if anyone who has had the same warranty denied by pylontech reports it to the ACCC, then maybe someone else might actually get the warranty they paid for from Pylontech. The more people who do report them the better the odds of the ACCC taking action.
Here is my reasoning.
1) If the battery BMS is passive only which Pylontech have informed me, then the battery protection is only for a very short time (as my logs show a 4 second window between entries in some cases) and not a true disconnect as i would expect, then a lot of the errors they claim void the warranty would not have occurred at all. All the extra over voltage entries occurring due to this, would lessen my entries 30 fold if i didn't make changes to the inverter and just restarted the batteries no knowing what had happened.
2)If the battery does not disconnect how is a end user to know when a over voltage event has ever happened? Is the user required to sit in front of the unit staring at the little red error LED waiting for it to go on for the 3 seconds that the error is happening over before the BMS resets and things return to normal status?
3) Pylontech does not make the Batteryview software publicly available for people to check the errors on the batteries to find any faults to correct.
4) having a passive BMS that does not disconnect the battery is misleading and unsafe. I and I'm sure plenty of others purchased these batteries because they thought the BMS would protect the battery against most of the potential problems that do damage to the cells.
5) Saying you have to have an approved inverter when they don't publish what inverters they do support up front. And if they did and they change what brands they support would your support inverter at time of purchase be claimed as a unsupported inverter years later when you try to make a claim?
Good luck @OzzyMozzy

Just wanted to let you all know that i have reported Pylontech to the ACCC over this matter. Though they won't help my situation, i do think if anyone who has had the same warranty denied by pylontech reports it to the ACCC, then maybe someone else might actually get the warranty they paid for from Pylontech. The more people who do report them the better the odds of the ACCC taking action.
Here is my reasoning.
1) If the battery BMS is passive only which Pylontech have informed me, then the battery protection is only for a very short time (as my logs show a 4 second window between entries in some cases) and not a true disconnect as i would expect, then a lot of the errors they claim void the warranty would not have occurred at all. All the extra over voltage entries occurring due to this, would lessen my entries 30 fold if i didn't make changes to the inverter and just restarted the batteries no knowing what had happened.
2)If the battery does not disconnect how is a end user to know when a over voltage event has ever happened? Is the user required to sit in front of the unit staring at the little red error LED waiting for it to go on for the 3 seconds that the error is happening over before the BMS resets and things return to normal status?
3) Pylontech does not make the Batteryview software publicly available for people to check the errors on the batteries to find any faults to correct.
4) having a passive BMS that does not disconnect the battery is misleading and unsafe. I and I'm sure plenty of others purchased these batteries because they thought the BMS would protect the battery against most of the potential problems that do damage to the cells.
5) Saying you have to have an approved inverter when they don't publish what inverters they do support up front. And if they did and they change what brands they support would your support inverter at time of purchase be claimed as a unsupported inverter years later when you try to make a claim?
Good luck @OzzyMozzy

Funny enough i have had a issue with 2 US2000 batteries. I had to shut the system down because i knew i didn't have enough power to last the night and wanted to preserve the charge for the next morning to use. Shutdown at 34% SoC and startup 7 hours later showed 2 batteries at 4% SoC. Logs showed before shutdown the charge was at 34% and 4% the next entry hours later.
Contacting Pylontech they had me download and send them the logs. which i done over 2 days as they took so long for the first two batteries to download and bad weather meant i wanted to conserve power. They have said "We actively hope to solve your problem, but two of your batteries have been recorded as frequently overcharged and I have found that your inverter MPPsolar 7248Max is not in our compatibility list, these are signs of improper use and will not be covered by the warranty."
I responded staiting that the inverters are in fact Voltronic axpect rebadged which are on their supported list and that any over voltage should have been handled by the BMS to prevent any damage. The really annoying part of this though the over voltage in my case was done 3 years ago before i even brought the batteries and not a ongoing problem (no over volt in the 2.5 years i have had the units and only 4 other events in this period).
There response "Our battery's passive protection mechanism, MOSFET, is only activated when the battery parameters are extremely abnormal (Short circuits, high currents, high voltages, etc. that can damage the circuit and may cause safety events). The battery BMS only uploads its own voltage, recommend charge and discharge current  to the inverter,, and the time to stop chargind/discharging is controlled by the inverter. Therefore, if the battery is still being charged despite reaching the alarm value, the voltage at the inverter must be higher than 54V (otherwise there would be no voltage difference between the battery and the external power source and it therefore would not be charged) as well as inverter does not react to the data uploaded by the battery according to the preset logic."
So to me the high voltage (54v) that the batteries received over a 17 day period in 2020 were not a high enough value for their BMS to worry about so meaning a very low chance of a problem occurring, causing them to say the warranty is not valid is just wrong.
Will be watching to find out how they treat you.

Funny enough i have had a issue with 2 US2000 batteries. I had to shut the system down because i knew i didn't have enough power to last the night and wanted to preserve the charge for the next morning to use. Shutdown at 34% SoC and startup 7 hours later showed 2 batteries at 4% SoC. Logs showed before shutdown the charge was at 34% and 4% the next entry hours later.
Contacting Pylontech they had me download and send them the logs. which i done over 2 days as they took so long for the first two batteries to download and bad weather meant i wanted to conserve power. They have said "We actively hope to solve your problem, but two of your batteries have been recorded as frequently overcharged and I have found that your inverter MPPsolar 7248Max is not in our compatibility list, these are signs of improper use and will not be covered by the warranty."
I responded staiting that the inverters are in fact Voltronic axpect rebadged which are on their supported list and that any over voltage should have been handled by the BMS to prevent any damage. The really annoying part of this though the over voltage in my case was done 3 years ago before i even brought the batteries and not a ongoing problem (no over volt in the 2.5 years i have had the units and only 4 other events in this period).
There response "Our battery's passive protection mechanism, MOSFET, is only activated when the battery parameters are extremely abnormal (Short circuits, high currents, high voltages, etc. that can damage the circuit and may cause safety events). The battery BMS only uploads its own voltage, recommend charge and discharge current  to the inverter,, and the time to stop chargind/discharging is controlled by the inverter. Therefore, if the battery is still being charged despite reaching the alarm value, the voltage at the inverter must be higher than 54V (otherwise there would be no voltage difference between the battery and the external power source and it therefore would not be charged) as well as inverter does not react to the data uploaded by the battery according to the preset logic."
So to me the high voltage (54v) that the batteries received over a 17 day period in 2020 were not a high enough value for their BMS to worry about so meaning a very low chance of a problem occurring, causing them to say the warranty is not valid is just wrong.
Will be watching to find out how they treat you.

Funny enough i have had a issue with 2 US2000 batteries. I had to shut the system down because i knew i didn't have enough power to last the night and wanted to preserve the charge for the next morning to use. Shutdown at 34% SoC and startup 7 hours later showed 2 batteries at 4% SoC. Logs showed before shutdown the charge was at 34% and 4% the next entry hours later.
Contacting Pylontech they had me download and send them the logs. which i done over 2 days as they took so long for the first two batteries to download and bad weather meant i wanted to conserve power. They have said "We actively hope to solve your problem, but two of your batteries have been recorded as frequently overcharged and I have found that your inverter MPPsolar 7248Max is not in our compatibility list, these are signs of improper use and will not be covered by the warranty."
I responded staiting that the inverters are in fact Voltronic axpect rebadged which are on their supported list and that any over voltage should have been handled by the BMS to prevent any damage. The really annoying part of this though the over voltage in my case was done 3 years ago before i even brought the batteries and not a ongoing problem (no over volt in the 2.5 years i have had the units and only 4 other events in this period).
There response "Our battery's passive protection mechanism, MOSFET, is only activated when the battery parameters are extremely abnormal (Short circuits, high currents, high voltages, etc. that can damage the circuit and may cause safety events). The battery BMS only uploads its own voltage, recommend charge and discharge current  to the inverter,, and the time to stop chargind/discharging is controlled by the inverter. Therefore, if the battery is still being charged despite reaching the alarm value, the voltage at the inverter must be higher than 54V (otherwise there would be no voltage difference between the battery and the external power source and it therefore would not be charged) as well as inverter does not react to the data uploaded by the battery according to the preset logic."
So to me the high voltage (54v) that the batteries received over a 17 day period in 2020 were not a high enough value for their BMS to worry about so meaning a very low chance of a problem occurring, causing them to say the warranty is not valid is just wrong.
Will be watching to find out how they treat you.