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Old 05-17-2017, 11:25 AM   #1
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Solar lines have disconnected


Recently took my 5.0 TA out of storage and noticed my Solar panel was not charging batteries(per tiny symbol on panel)After much searching on forum I fianally cleaned out my cabinet which houses the GoPower wires ,squeezed my head in and found this.
It appears that a meltdown began on the top insert spot for the solar wire.
The wires are now hanging freely in the back touching nothing and camper is planted not going anywhere right now.I do have the battery lines secure which you can see in one of the photos.
All this said I see the problem and I would like to try to fix it. I just need the expertice of this forum...I think.

Am I kidding myself?My background is in Common Sense and Caution.
Thanks Yall
AS
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Old 05-17-2017, 11:46 AM   #2
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Quote:
Originally Posted by WHATARIDE View Post

Recently took my 5.0 TA out of storage and noticed my Solar panel was not charging batteries(per tiny symbol on panel)After much searching on forum I fianally cleaned out my cabinet which houses the GoPower wires ,squeezed my head in and found this.
It appears that a meltdown began on the top insert spot for the solar wire.
The wires are now hanging freely in the back touching nothing and camper is planted not going anywhere right now.I do have the battery lines secure which you can see in one of the photos.
All this said I see the problem and I would like to try to fix it. I just need the expertice of this forum...I think.

Am I kidding myself?My background is in Common Sense and Caution.
Thanks Yall
AS
I would plan on replacing your solar controller . The combination of an arcing fault and overheating is seldom good for electronics or terminals . Most likely the wire terminals were never tightened and then properly torqued to spec.
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Old 05-17-2017, 01:01 PM   #3
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Replacing the solar controller might well be in order. You mention you had to clean out that area, were items stored against it? If so, I would do something that would stop that from happening, as that too could have caused the loose connection, though they might not have been tightened enough upon install.
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Old 05-17-2017, 01:07 PM   #4
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When installing a stranded wire in a lug / screw terminal ,
install the bare conductor into the terminal , tighten terminal screw ,
wiggle the wire in the terminal so the strands set , then retighten the terminal screw.
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Old 05-17-2017, 01:44 PM   #5
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When you say "meltdown" do you mean shorted or melted wiring? I can't see any melting. Just looks like the wire came out of the terminal. Did you reconnect it to see if the controller still works?

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Old 05-17-2017, 04:05 PM   #6
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The case of the controller around the panel "+" terminal certainly looks melted - so much that the terminal shifted and elongated the screw hole - and the screw appears discoloured. If only the case is affected, and the terminal is still sound, then maybe the controller is okay... but I would take Steve's advice (which is good general rule ) and plan on a controller replacement.
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Old 05-17-2017, 04:31 PM   #7
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Originally Posted by Brian B-P View Post
The case of the controller around the panel "+" terminal certainly looks melted - so much that the terminal shifted and elongated the screw hole - and the screw appears discoloured. If only the case is affected, and the terminal is still sound, then maybe the controller is okay... but I would take Steve's advice (which is good general rule ) and plan on a controller replacement.
That's what I get for looking at the photos on a phone instead of my computer. Yes, the corner of the plastic does look like it melted.
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Old 05-17-2017, 06:04 PM   #8
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Before shelling out $$$ for a new controller try reinstalling the wires. It is possible that the damage was only to the immediate area of the connection and not the internal electronics.

I notice that one of the wire has a small length of exposed wire. I would suggest cutting off some additional insulation so that the bare wire seats all the way into the hole. This may be the cause of the overheating - not enough contact between the wire and the connection.

Best of Luck!

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Old 05-20-2017, 05:34 PM   #9
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If you look at the last pic it appears distorted where the firt wire would be placed.Its not that clear in the pic.
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Old 05-20-2017, 05:52 PM   #10
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I looked at the photo before making my original post ! . The terminal has been overheated (color) , appears distorted and there is evidence of melted plastic .
Classic loose wire / terminal . At the least the terminal will need to be replaced and the internal connection repaired.
Again plan on replacing the controller if for no other reason than safety.
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