Frying 30A PWM Charge Controller
Last year October, I purchased the Renogy 400W Solar Panel Mono Starter Kit, along 4 Duracell SLIGC115 6V batteries and a Power Brite 3500W MSW Inverter to use at our remote off grid cabin.
In the beginning everything worked great. We purchased a Vassani 9.9 cu ft refrigerator plugged into the inverter working flawlessly. The refrigerator pulls 329kWh per year. Over the winter period we lost power more frequently. Then we noticed that our original Renogy 30A PWM was not charging the batteries. We replaced with another brand 30A PWM, to find that the DC + (input) melted due to what seems like over current. At that time there was no fuse/break on that DC in line from the batteries to the DC + on the charge controller. Last week I then replaced the charge controller with another 30A PWM and installed a 30A breaker on the DC + line. Everything seemed to be going alright and charging was going up. What I noticed at that time is that with the sun going down, our voltage level on the batteries dropped quickly to 60%.
Upon arriving this past weekend, I noticed a red light on the battery status, over discharge, and the DC + was melted again, but the breaker did not trip. The batteries had not been charging and were again depleted to around 60% or below.
I have no idea what is giving the DC + input an over current, or melting, condition. Below is my configuration. Is there anything you can think of that would give me the problem of melting the DC Input? (see controller pictures below)
Solar Setup - 2016
(4) Renogy 100 Watt 12 Volt Monocrystalline Panels
- Less than 20 ft from Charge Controller
30A PWM Renogy Charge Controller
- 30A breaker on DC + input
- No fuse/breaker on Solar Panel + input
4 Duracell SLIGC115 6V @ 230AH
- Series and Parallel for 12V @ 460AH
Power Bright Power 3500 Watt 12V - Modified Sine Wave Inverter
- 200A Inline Fuse from battery to Invert + input
PWM 30A Charge Controller (DC + melted)
Any help would be greatly appreciated.