12 hours ago
- The author and their family have lived off-grid for 46 years, starting with a small 2-amp solar system and now using a 100-amp system.
- A remote meter showed fluctuating readings, indicating a problem; later, a burning smell and fault code on the solar charge controller revealed overheating wires.
- Two bad connections at different locations caused wires to overheat due to increased resistance, despite being properly sized for 100 amps.
- The power formula P = I²R explains how even small resistance increases can generate extreme heat at high currents, e.g., 3000 watts vs. 500 watts.
- Poor connections from loose terminals or corrosion can lead to self-reinforcing overheating and damage over time.
- Recommendation: Check and re-tighten all connections after 6 months, especially in high-current systems, to prevent issues.