What’s that smell?

Payson, AZ (Solar Panel blowing specified 30 amp 4to1 fuse)

I hadn’t cleaned my panels after all the rain in Alpine, AZ so I decided in the morning to get up on the ladder before it got too hot.

Around 10 am I noticed that the amperage had dropped drastically and started to troubleshoot the issue.

I recycled all the circuit breakers and emergency solar connection cut-off switch, checked the Anderson connection (yellow), and found nothing.

I pulled the A/C housing cover (6 screws) and loosed the passenger side ceiling panel divider (see receipt for proper name) and pulled out the center ceiling panel between the A/C unit and the CO arch.

I then proceeded to remove the intermediate panel that the 4to1’s were mounted on (see picture #) and proceeded to disconnect one of the solar panel set of cables so I could check the amperage.

I found excessive amperage on each of the 4 panels and then noticed that the positive 4to1 (with the 30 amp inline fuse that was specified by the manufacturer) was looking a bit off.  Turns out the fuse had blown but not before distorting a good portion of its outer body.

I called the manufacturer and described my issue along with the fact that I was showing nearly 8+ amps coming from each panel.  I was put on hold and the tech started looking into the issue but not before saying “It shouldn’t be producing that much amperage.

Back and forth chit-chat with elevation 5000’+, the temperature with NO clouds, etc.  Requests for pictures and the opening of a ticket.  Blah Blah Blah.

I’m barely a week in on a 2-month trout stream scouting trip, hundreds of miles from home and the result from my phone call was I started getting the CYA routine via email.

Needless to say, I’m not in a good mood when a fellow camper shows up at my door wanting to help.  I’m camping at an ELKS lodge in Payson and this gentleman just says “Let’s just fix the problem”.  All I can say is I couldn’t find anything out of order with the suggestion considering his years of experience!  KISS - Out come the parrot bills, the crimpers, electrical tape, etc.

A trip to the nearby NAPA store to get an automotive fuse (40 amp was all they had which I later downgraded to a 30 amp during my travels), some more connectors, etc. as well as a compatible buss-bar that was delivered the next morning and I was buttoning up the ceiling.  In addition, I added some strain relief hardware to keep the new repair to keep the assembly nice and stable in the ceiling.

I was up and running enjoying the output of my solar panels, grinding my espresso beans, and having a dark and velvety (whole bean package text) cup of Lavazza Perfetto thanks to my Flair the very next morning.

Ain‘t life sweet?