Surprising fault found

[Jake Royd]

I have a 200w panel , a two channel PWM controller connected to each battery using the terminal posts in the distribution board.
Recently the indicator LEDs have been flashing red (for which the is no meaning in the controller manual) or flashing green , red or amber. Sometimes one sometimes both.
I suspected a failing controller and proved that by removing and replacing the inline fuses between the controller and the batteries, reset the system.
Or so I thought.
Nice and sunny now and both batteries only showing 2/3 full or about 12.5v.
So I 'reset' again but no led lit on the leisure battery side.
A quick check with a multimeter showed 0 volts with the fuse inserted.
Then it dawned on me.
It's the fuse holder that's faulty.
If the controller can't determine the leisure battery presence then it's not going to charge the cab battery either.

So short term I have bent the fuse legs a bit to ensure contact. All working fine
I have ordered a better quality 2 way fuse holder.

Thought to mention it as it was not at all what I had originally assumed.
Electrical gremlins are often simple , it's locating them that takes time and effort.

 

[ambulancekidd]

Please let us know how things turn out, I'm sure that'll be helpful to other forum members.

 

[Jake Royd]

Well it's done.
This is the before.

I think I can see the problem on the close up of the socket , it's just poor quality.
Here is the upgrade.

Yes , to crimp those connectors on was bloody difficult.
However I now have much better quality connections which should be reliable.
Also going from mini fuses to full size is a good thing.

 

[68c]

Difficult to work out where those two red wires are coming from/going to, a wall panel, battery box? If you have access I would replace them with longer wires, then you will have enough slack to mount the fuse holder somewhere solid to avoid future problems. May be an opportunity to fit thicker cabling.

 

[Richard n Ann]

I like midi fuses. They have bolt on connectors, much better

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[Jake Royd]

Difficult to work out where those two red wires are coming from/going to, a wall panel, battery box? If you have access I would replace them with longer wires, then you will have enough slack to mount the fuse holder somewhere solid to avoid future problems. May be an opportunity to fit thicker cabling.

The two red wires on the LHS come from the solar controller and have plenty of spare length.
The two from the distribution box on the RHS go to the +B1 and +B2 terminals and are too short really. But it will do for the time being , they are quite stiff and should not suffer fatigue. 4mm2. I'm not certain I could get 6mm2 on there physically.
It's quite a careful and slow job to dismantle the distribution box to get to the terminals , so I may do it another time. I am using the cable left over from the original fuse holder.
I must say the engagement of the fuse legs in the holder is way better on the new fuse holder.