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06-27-2011, 05:41 PM
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#1
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Mini Rivet
1975 25' Tradewind
Holland
, Michigan
Join Date: Sep 2008
Posts: 273
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Help my solar controller caught on fire
Please help,
I recently installed a SunSaver 6 solar controller and this past weekend after having been set up for camping for a few hours all the 12 volt power went out. I leisurely moseyed on back to the fuse panel see what had happened, as soon as I opened the bathroom door I could smell burning rubber. I opened the closet door to get at the fuse panel and smoke billowed out, I opened the door to the fuse panel and all I could see through the smoke was bright electrical sparks and fire at the solar controller.
I had my brother go unplug the camper and I just starting yanking wires out of the solar controller, even after pulling wire, unplugging and removing fuses the solar controller just keep on burning. I had to leave after that, I couldn't hold my breath any longer and I could not breathe through the smoke.
When I finally go back in the camper to survey the damage there wasn’t much, the solar controller looked a little charged. I would have thought with that much nasty stinky smoke the controller would be completely melted.
Any way what the hell did I do wrong to make this thing have a melt down.
Below are photos of the box and a schematic of the wiring.
Would much appreciate your help on this
My first thread on this matter
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06-27-2011, 06:33 PM
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#2
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Mini Rivet
1975 25' Tradewind
Holland
, Michigan
Join Date: Sep 2008
Posts: 273
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By the way I didn't blow a single fuse
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06-27-2011, 08:31 PM
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#3
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Rivet Master
1999 34' Excella
Joshua
, Texas
Join Date: Apr 2002
Posts: 548
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Your charger maybe sized too small.....the better ones on the market are...
Morningstar Corporation » TriStar MPPT
__________________
History doesn't repeat itself, people do!
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06-27-2011, 08:35 PM
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#4
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Rivet Master
2008 27' Classic FB
1959 22' Flying Cloud
fairview
, New Mexico
Join Date: Mar 2005
Posts: 575
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It looks like the load wire is the one burnt. Why would you have a load on a 6 amp system? I doubt that you would have much of an excess of power. That amount of solar is just enough for one battery and none to spare.
__________________
Avion C11
1959 Flying Cloud 1969 Tradewind
1973 Safari
1983 34 ft Limited
2004 F250 superduty ext cab
2014 F350 longbed superduty crewcab
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06-27-2011, 09:03 PM
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#5
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steel/aluminum fabricator
2004 22' International CCD
Penticton
, British Columbia
Join Date: Oct 2010
Posts: 133
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I think something shorted out behind the sunsaver plate.
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06-27-2011, 09:22 PM
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#6
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More than one rivet loose
Currently Looking...
Los Alamos
, New Mexico
Join Date: Feb 2006
Posts: 3,756
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The Sunsaver 6 is only meant for 6 amps. You do not wire a load in the a trailer. The load comes off the battery. The way you have it wired your DC load runs through the Sunsaver. Hence the "fire"
__________________
Michelle TAC MT-0
Sarah, Snowball
Looking for a 1962 Flying Cloud
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06-27-2011, 09:30 PM
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#7
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3 Rivet Member
1974 27' Overlander
Sault ste Marie
, Ontario
Join Date: Jun 2004
Posts: 166
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Your running the entire 12V load through the charge controller, I don't really think that's the way to do it. T'was mine, I'd run the load for the fuse panel from the positive bus and just have the charge controller feed the bus. That way, heavy power demand will come directly from the batteries and not through the controller.............Phil.
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06-27-2011, 10:07 PM
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#8
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Mini Rivet
1975 25' Tradewind
Holland
, Michigan
Join Date: Sep 2008
Posts: 273
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Thanks everyone for the information, as you can see I know just enough to make me dangerous.
I think my controller , 6A, is of the right size, here are the specs to my solar panel.
Module Catalogue Number BP250/1 BP250/2
Typical Peak Power (Pmax) 50.00W
Voltage @ maximum power (V mp) 17.00V
Current @ maximum power (I mp) 2.94A
Short-circuit current (I sc) 3.22A
Open-circuit Voltage (V oc) 21.20V
Here is how I believe it should be wired, please correct me if I am wrong.
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06-28-2011, 09:59 AM
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#9
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More than one rivet loose
Currently Looking...
Los Alamos
, New Mexico
Join Date: Feb 2006
Posts: 3,756
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That looks much better. You should have a fuse in the line from solar panel to the Sunsaver and a fuse from the Sunsaver to the main buss. The solar panel fuse should be near the solar panel.
If you plan to add more panels you should look at a much larger controller.
I have a Morningstar Tristar PWM 45A controller. I am running just under 20A at full sun. It runs nice and cool.
__________________
Michelle TAC MT-0
Sarah, Snowball
Looking for a 1962 Flying Cloud
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03-22-2016, 06:16 PM
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#10
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1 Rivet Member
Boardman, OR
, Oregon
Join Date: Mar 2016
Posts: 6
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Quote:
Originally Posted by arodriguez60
It looks like the load wire is the one burnt. Why would you have a load on a 6 amp system? I doubt that you would have much of an excess of power. That amount of solar is just enough for one battery and none to spare.
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Why would he put a load on a 6 amp system? why wouldn't you? how else does he use the low voltage disconnect if he didn't? the failure was from the charge controller, the OP did nothing wrong.
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03-22-2016, 06:20 PM
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#11
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1 Rivet Member
Boardman, OR
, Oregon
Join Date: Mar 2016
Posts: 6
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I wouldn't listen to these guys, if you connect straight to the battery than you no longer have the low voltage disconnect to protect your battery bank from being destroyed. you are supposed to wire it to your charge controller which you did so you did nothing wrong. the fault is only through the controller and nothing else, 6A was just too low and the controller is a POS, I have the 10 A version used with a 100 watt mono panel connected to a 2/0 cable which used to be for my car's sub amp, it didn't fail for the few months I used it.
Quote:
Originally Posted by bmklawt
Thanks everyone for the information, as you can see I know just enough to make me dangerous.
I think my controller , 6A, is of the right size, here are the specs to my solar panel.
Module Catalogue Number BP250/1 BP250/2
Typical Peak Power (Pmax) 50.00W
Voltage @ maximum power (V mp) 17.00V
Current @ maximum power (I mp) 2.94A
Short-circuit current (I sc) 3.22A
Open-circuit Voltage (V oc) 21.20V
Here is how I believe it should be wired, please correct me if I am wrong.
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03-22-2016, 08:33 PM
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#12
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Rivet Master
2014 31' Classic
2015 23' International
2013 25' FB International
Apache Junction
, Arizona
Join Date: Sep 2012
Posts: 6,223
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We used the Morningstar TriStar 60 MPPT controller in the Classic with 800 watts of solar panels. We will add another 100 watt panel in May. The Blue Sky 3024iL is sufficient for the five 100 watt panels on the 23D. We sized the solar charge controller and associated wires to the output of the solar panels.
__________________
WBCCI Life Member 5123, AIR 70341, 4CU, WD9EMC
TV - 2012 Dodge 2500 4x4 Cummins HO, automatic, Centramatics, Kelderman level ride airbag suspension, bed shell
2014 31' Classic w/ twin beds, 50 amp service, 1000 watt solar system, Centramatics, Tuson TPMS, 12" disc brakes, 16" tires & wheels
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03-22-2016, 11:00 PM
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#13
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Rivet Master
2015 30' Classic
Pleasanton
, California
Join Date: Jan 2015
Posts: 745
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thecatsandi is correct, you shouldn't connect the load to the battery. Doing so probably causes current to flow through your solar controller and not directly from the battery.
Another problem I see is that you do not have adequate clearance to allow proper air circulation as required in the manual. Either you should relocate your controller or open up the top of the enclosure to allow airflow.
The controller you selected should work fine once you get a replacement
__________________
Al, K6IV
2015 30' Classic, "Chez Nu"
2014 RAM 2500 w/Cummins Diesel
ProPride Hitch, 400 W Solar
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03-23-2016, 12:14 AM
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#14
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4 Rivet Member
Currently Looking...
ottawa (greely)
, Ontario
Join Date: Feb 2012
Posts: 390
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Maximum load 6-10 amps ,you have how many 20 amp fuses +other fuses on the load side !no wonder it melted! Plus we need to know wire sizes, and were they come from ,I think we need the wiring schematic from the manufacture. As I think it can be wired different to work but all loads should come from the battery not the charge controller ,I think this controller has a feature ( load side ) to control a small load such as a ( one ) light or fan 6 amps or maximimum 10 depending on model, also you need to due a better job of wiring as I see you have a wire insulator part touching metal your just looking for it to rub through ,this is a trailer going down bumpy roads .also you have the jumper in for a sealed type battery this jumper must be removed if your charging a flooded lead acid battery as there is a different charging voltages for sealed versus flooded,this didn't cause your problem ,but could be another down the road.
__________________
2012 silverado ext cab 4x4 ,5.3 L , 6 speed trans,3:42 final drive,tow package standard box 6 1/2 foot . 2014 honda forza 300 scooter, #2 2015 honda crf 250 L (Dual sport)
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03-23-2016, 06:15 AM
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#15
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Rivet Master
Commercial Member
Vintage Kin Owner
Naples
, Florida
Join Date: Dec 2005
Posts: 7,508
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Has anyone noticed the date of the original discussion??
__________________
lewster
Solar Tech Energy Systems, Inc.
Victron Solar Components and Inverters, Zamp Solar Panels, LiFeBlue and Battle Born Lithium Batteries, Lifeline AGM Batteries
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03-23-2016, 06:57 AM
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#16
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Full Time Adventurer
2007 27' International CCD FB
Nomadic
, USA
Join Date: Jul 2013
Posts: 2,748
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Quote:
Originally Posted by lewster
Has anyone noticed the date of the original discussion??
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I was wondering why someone dug up this ancient post.
__________________
Family of 5 exploring the USA with a Ram Power Wagon & Airstream in tow.
OUR BLOG | INSTAGRAM
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03-23-2016, 07:55 AM
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#17
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4 Rivet Member
Currently Looking...
ottawa (greely)
, Ontario
Join Date: Feb 2012
Posts: 390
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The snowball only gets bigger as you roll it in the fresh wet snow ! What a mess wiring and snowball! Thank Lewster or pointing out the date
__________________
2012 silverado ext cab 4x4 ,5.3 L , 6 speed trans,3:42 final drive,tow package standard box 6 1/2 foot . 2014 honda forza 300 scooter, #2 2015 honda crf 250 L (Dual sport)
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03-23-2016, 09:29 AM
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#18
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Rivet Master
2006 23' Safari SE
Biloxi
, Mississippi
Join Date: Nov 2011
Posts: 8,278
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New post was made by a new member starting out by insulting other members and apparently not reading the entire thread. Go figure.
__________________
MICHAEL
Do you know what a learning experience is? A learning experience is one of those things that says "You know that thing that you just did? Don't do that."
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03-23-2016, 10:37 AM
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#19
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Full Time Adventurer
2007 27' International CCD FB
Nomadic
, USA
Join Date: Jul 2013
Posts: 2,748
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Quote:
Originally Posted by AWCHIEF
New post was made by a new member starting out by insulting other members and apparently not reading the entire thread. Go figure.
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He should fit right in then.
Also he used a cable from his "car's amp" which means he's a knowledgeable expert.
See, just keeping the snowball going here.
__________________
Family of 5 exploring the USA with a Ram Power Wagon & Airstream in tow.
OUR BLOG | INSTAGRAM
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03-23-2016, 10:47 AM
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#20
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Rivet Master
Commercial Member
Vintage Kin Owner
Naples
, Florida
Join Date: Dec 2005
Posts: 7,508
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Not my place to comment on the OP's wiring job....... I leave that to you guys!! :-))
Lew Farber
RVIA/RVDA Nationally Certified Master Tech
ABYC Certified Master Marine Electrician
Master Tech Energy Systems, Inc.
AM Solar Certified Installation Center*AMS Lithium Batteries
Lifeline AGM Batteries**Magnum Inverters
541-490-6357
__________________
lewster
Solar Tech Energy Systems, Inc.
Victron Solar Components and Inverters, Zamp Solar Panels, LiFeBlue and Battle Born Lithium Batteries, Lifeline AGM Batteries
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