Installed renogy solar; waterproof 60amp fuse issue? Batteries not charging

Hi all,

Purchased 2x 1000watt Renogy panels, Renogy solar lithium battery charger (12vlt and 24volt), the 24 volt output device and Bluetooth components. And through a friend who builds vans - got my entire system fitted. Here are some photos below. I’m working on a diagram now.

Basically on hot days my water 60amp switch pops and I have to physically re engage it to get the system working smooth again. (In the photo it’s the black) now after this happening time and again even while re engaged the system is not allowing batteries to charge quick enough. Either the fuse is damaged or the solar controller is faulty. I might be wrong

Could you assist me with an idea on what could be wrong? I’m somewhat a newbie at this and appreciate your help!

Thanks in advance for your help.
JT

From personal experience with both of those circuit breakers, both are junk and do not hold the rated amperage. For your safety and the safety of your equipment, please please please, get a good, reliable DC rated breaker.

Thank you for the advice! I’ll look some up now. Any recommendations allowed?

Please take a picture that shows the fuse block in greater detail.
I see what appears to be a bunch of 20 and 30 amp fuses with wires that appear to be too small for the ratings.
Also the feeder appears to be 10 awg which I would fuse no higher than 30 amps.

John Frum said:

Please take a picture that shows the fuse block in greater detail.
I see what appears to be a bunch of 20 and 30 amp fuses with wires that appear to be too small for the ratings.
Also the feeder appears to be 10 awg which I would fuse no higher than 30 amps.

Click to expand...

Can you explain what the feeder is? I take it to be the the positive wire coming straight from the panels.

JahneTheron said:

Can you explain what the feeder is? I take it to be the the positive wire coming straight from the panels.

Click to expand...

The feeders are the wires that connect the fuse block to the main busbars.
The positive feeder starts at the positive busbar goes through the audio style 50 amp breaker and terminates at the fuse block.
I can't sea where the negative feeder goes.
The fuse block is the thing with green and yellow automotive style fuses in it.

@JahneTheron in order to properly size the breakers we need to know the wire gauges.
The are usually printed on the wires.
You may also need to replace some wires if they are undersized for their application.

@JahneTheron I'm just going to come out and say it.
That ANL fuse makes me very sad.
Your system has multiple safety issues that I can see and I suspect there are more that I can't see.

Any name you wish said:

From personal experience with both of those circuit breakers, both are junk and do not hold the rated amperage. For your safety and the safety of your equipment, please please please, get a good, reliable DC rated breaker.

Click to expand...

hows this one; DC Surge Protector SPD SXRR Indoor AAR Terminal 50 Vdc, Single-Mode, 25 kA SASD

This is the setup, I’ve taken out the 12vlt wires. But even before that, the 60a fuse would pop.
What is a safe alternative fuse?
How do I drain power from the system to switch it out?
The cable sizes I am aware of (as I did not install) are 12 AWG and larger. If anyone is willing to help, I would compensate. Really in need of assistance. JT 725-780-5407

The solar install materials used as per shop:
1) 12V 200Ah Lithium Iron LiFePO4 Deep Cycle Battery, Built-in 100A BMS, 2000+ Cycles, 280amp Max, Perfect for RV, Solar, Marine, Overland, Off-Grid Application
Quantity: 2
Price: $1511.42
2) Upgraded 300A 12 Way Blade Fuse Block Fuse Box with 2 Positive Power Inputs Negative Bus, Electop 12 Circuit Fuse Holder ATC/ATO Fuse Block Panel with LED Indicator for 12V/24V Car Truck Boat Marine
Quantity: 1
Price: $27.98
3) Renogy DC On-Board Charger with MPPT Gel, AGM, and Lithium Batteries, w, Using Multi-Stage Charging, 12V 50A
Quantity: 1
Price: $290.45
4) (Red & Black) 5/16" 4 Stud Power Distribution Block -BUSBAR- with Cover - Made in The USA
Quantity: 1
Price: $39.49
5) Renogy BT-2 Bluetooth Module RJ45 Communication Port Wirelessly Monitor and Adjust Compatible Solar Charge Controllers, RS485
Quantity: 1
Price: $33.62
6) Renogy 200 Watt Solar Panel 12 Volt Monocrystalline High-Efficiency Module PV Power for Camper, Vehicle Caravan and Other Off-Grid Applications, 200W, 63.8×25.9×1.4 in
Quantity: 2
Price: 576.12
7) SELTERM 4 AWG 3/8" Stud (Wide Pad) (10 pcs.) UL Marine Grade Wire Lugs, Battery Cable Ends, Tinned Copper Eyelets, Tubular Ring Terminal Connectors [B40]
Quantity: 1
Price: 14.30
8) USMEI Dual QC3.0 USB Charger Socket, 36W Waterproof Quick Charge 3.0 Power Outlet Adapter for 12V/24V Car Boat Marine Motorcycle ATV RV Campers Tractors Truck Golf-Cart etc
Q: 1
P: 16.29
9) Battery Capacity Monitor, DROK 10-100v Battery Meter, 12v 24v 48v Battery Power Percentage Voltage Fahrenheit Temperature Indicator Gauge
Q: 1
P: 17.75
10) BougeRV 10 Feet 10AWG Solar Extension Cable with Female and Male Connector with Extra Free Pair of Connectors Solar Panel Adaptor Kit Tool (10FT Red + 10FT Black)
Q: 1
P: 21.93
10) 300A Power Switch M Series Battery Switch, Used for Battery Switch Single Circuit Marine On/Off Red
Q: 1
P: 36.56
11) BougeRV Solar Connectors Y Branch Parallel Adapter Cable Wire Plug Tool Kit for Solar Panel
Q: 1
P: 8.35
12) SELTERM 4/0 AWG 3/8" Stud (25 pcs.) UL Marine Grade Wire Lugs, Battery Cable Ends, Tinned Copper Eyelets, Tubular Ring Terminal Connectors [B94]
Q: 1
P: 49.94
13) Renogy 30A Male and Female Connector Waterproof in-Line Fuse Holder, 30A, Black
Q: 1
P: 16.11
14) Glarks 50pcs 12-10 Gauge #10 Fork Spade Nylon Heat Shrink Waterproof Quick Disconnect Electrical Insulated Crimp Terminals Connectors Assortment Kit
Q: 1
P: 11.44
15) GS Power 12 Gauge Wire (12 AWG) - 100 Foot, Pure Copper, Stranded Electrical Wiring for Speaker, Automotive, Trailer, Stereo and Home Theater Applications - Red/Black
Q: 1
P: 50.11
16) BOJACK 2 Pcs 400A Clear Shell ANL Fuse Holder and 2 Pcs 400 Amp 32 VDC ANL Fuses for Audio and Video System
Q: 1
P: 15.66
17) WNI 4/0 AWG 4/0 Gauge 5 Feet Black + 5 Feet Red Battery Welding Pure Copper Ultra Flexible Cable + 5pcs of 5/16" & 5pcs 3/8" Copper Cable Lug Terminal Connectors + 3 Feet Heat Shrink Tubing
Q: 1
P: 105.46
18) 4 Gauge 4 AWG 30 Feet Black Welding Battery Pure Copper Flexible Cable + 10pcs of 3/8" Tinned Copper Cable Lug Terminal Connectors + 3 Feet Black Heat Shrink Tubing
Q: 1
P: 65.53
19) WOHHOM 100 Amp Circuit Breaker with Manual Reset 12V-36V DC Waterproof Surface Mount for Car Audio Rv Marine Boat Truck Trolling Motors, 30-300A Car Speaker Resettable Fuse
Q: 1
P: 21.92
20) WOHHOM 60 Amp Circuit Breaker with Manual Reset 12V-36V DC Waterproof Surface Mount for Car Audio Rv Marine Boat Truck Trolling Motors, 30-300A Car Speaker Resettable Fuse
Q: 1
P: 19.83
21) WOHHOM 50A Audio Circuit Breaker Auto Car Stereo Inline Fuse Holders Inverter, Manual Reset 12V-24V DC for Automotive Marine Boat Audio System Protection (50A)
Q: 1
P: 14.61
22) Link Solar Weatherproof ABS Solar Double Cable Entry Gland for All Cable Types 2mm² to 6mm² for Solar Project on Rv, Campervan, Boat
Q: 1
P: 12.53
23) XOOL 2 Sets of Solar Panel Roof Mounting Z-Bracket with Nuts and Bolts for RV, Boat, Roof, Wall and Other Off Gird Roof Installation, Set of 4 Units
Q: 1
P: 17.71
24) Renogy 3000 Watt 12V DC to 120V AC Pure Sine Wave Inverter Charger w/LCD Display, 3000W, Lithium Battery Compatibility 9000W Surge
Q: 1
P: 858.12
25) 80/20 Inc, 3393, 10 Series, Bolt Assembly: 1/4-20 x .5" Button Head Socket Cap Screw (BHSCS) and Slide-in Economy T-Nut (25 Pack)
Q: 1

@JahneTheron please post a wide shot of the system.

Also can you please post a picture showing how the dc2dc charger connects to the starter battery?

JahneTheron said:

hows this one; DC Surge Protector SPD SXRR Indoor AAR Terminal 50 Vdc, Single-Mode, 25 kA SASD

Click to expand...

I believe this one is suitable for the 50A one. Size it appropriate to your load across that wire.


The 100A one, I am kinda partial to the Blue Sea Systems 187 Series & 285 Series Surface Mount & Panel Mount Circuit Breakers only because Blue Sea Systems has a better reputation for CB. I don't understand an ANL fuse on both the positive and the negative. The positive one looks bent at the wire end so I would expect it to get hot due to bad connection. Flat and surface area matters.

Are those Ampertime batteries? I don't know if they are or if you can disable the output on them through the BMS to make it a bit safer to disconnect.

JahneTheron said:

The solar install materials used as per shop:

Click to expand...

Tell us more about this "shop". You paid money to have the lowest quality possible fuses and circuit breakers selected? They charged you for bulk wire and bulk wire lugs it looks like, did they give you the extra supplies after charging you for them? Or just put those bulk items on every bill?

Lilikoi_Heavy_Industries said:

Tell us more about this "shop". You paid money to have the lowest quality possible fuses and circuit breakers selected? They charged you for bulk wire and bulk wire lugs it looks like, did they give you the extra supplies after charging you for them? Or just put those bulk items on every bill?

Click to expand...

They gave me a small box the extras, but not much left over seemed usful.

Any name you wish said:

I believe this one is suitable for the 50A one. Size it appropriate to your load across that wire.

NDB2Z-63 Series Miniature Circuit Breaker | Nader Circuit Breaker

The 100A one, I am kinda partial to the Blue Sea Systems 187 Series & 285 Series Surface Mount & Panel Mount Circuit Breakers only because Blue Sea Systems has a better reputation for CB. I don't understand an ANL fuse on both the positive and the negative. The positive one looks bent at the wire end so I would expect it to get hot due to bad connection. Flat and surface area matters.

Are those Ampertime batteries? I don't know if they are or if you can disable the output on them through the BMS to make it a bit safer to disconnect.

Click to expand...

Thanks for this info! Looks like ill have to get a secure box for this fuse. Probably added safety for sparks. Appreciate your help

JahneTheron said:

Thanks for this info! Looks like ill have to get a secure box for this fuse. Probably added safety for sparks. Appreciate your help

Click to expand...

Yes Ampere batteries! Little bigger than the other brands for the same amperage. Nxt time ill ask to go with the well-known brands

Any name you wish said:

I believe this one is suitable for the 50A one. Size it appropriate to your load across that wire.

NDB2Z-63 Series Miniature Circuit Breaker | Nader Circuit Breaker

The 100A one, I am kinda partial to the Blue Sea Systems 187 Series & 285 Series Surface Mount & Panel Mount Circuit Breakers only because Blue Sea Systems has a better reputation for CB. I don't understand an ANL fuse on both the positive and the negative. The positive one looks bent at the wire end so I would expect it to get hot due to bad connection. Flat and surface area matters.

Are those Ampertime batteries? I don't know if they are or if you can disable the output on them through the BMS to make it a bit safer to disconnect.

Click to expand...

I will attempt to drain the system and take them out. Is it worth swapping ANL fuses for something else?

John Frum said:

@JahneTheron please post a wide shot of the system.

Also can you please post a picture showing how the dc2dc charger connects to the starter battery?

Click to expand...

Thanks John ill post a photo when back at van after lunch. Appreciate your honesty and help !

You don't need to 'drain' the battery before working on the system.
Disable the inverter charger by disconnecting from shore power. Disconnect the solar positive input cable and engine feed cable to the Renogy DCC 50S, tape cable terminations to prevent accidental short circuits. Disconnect the negative cables at the battery. It's now safe to work on the system. Reconnect in reverse order, battery negatives first.

Although you have resionable batteries and equipment, the instalation is a mess and the inadequate beakers are causing issues.

You 'friend' who builds campers or his workforce has little understanding of over current protection, wiring standards, and best install pratice. It's sad that this happens but unfortunately it's all too common.

Before replacing the breakers with better quality alternatives , ( breakers or fuses), some investigation is needed to establish that the correct values are used with suitable cable.

The necessary rewire will need suitable cable and tools to add the terminations.

@JahneTheron we also need pictures of the ac distribution panel
Also we need pictures of the dc2dc charger with the covers over the wiring terminals removed.

John Frum said:

@JahneTheron please post a wide shot of the system.

Also can you please post a picture showing how the dc2dc charger connects to the starter battery?

Click to expand...

Here’s the way he attached to battery. One cable running straight to positive. It comes out the bottom left of the solar charger - goes to a fuse then onto the positive of vans (lead acid battery?) Is this ok?