Thanks Gordon,
Yes now that i look at the raw figures it puts me right on the line and makes sense as to the possible cause. I am in the process of making a bigger array with better match of 250 Watt panels so this is great to know as it changes my whole plan of wiring.
For now back to the current setup i will rewire it in the next day or so and see how it performs
Ray
Btw would really like to know how Kev's outcome was ?