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Old 09-30-2019, 04:12 AM   #21
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Originally Posted by hoppers4 View Post
My first thought on seeing the pictures was that the connection to the wire was loose and that the melted spot on the sensor was a result and not a cause.
I have had two automatic transfer switches fail in this exact same way in the past 9 years full time use. Loose lugs. I check mine annually now.
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Old 09-30-2019, 06:14 AM   #22
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Regardless of the outcome I will be going with an external pedestal mount from here on.
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Old 09-30-2019, 07:18 AM   #23
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I have had two automatic transfer switches fail in this exact same way in the past 9 years full time use. Loose lugs. I check mine annually now.
That's a really good point Ed! I'm going to be pulling covers on both units and checking connections. Also a good time to check terminal tightness on the converter/distribution panel.

Here's another one. My 30 amp power plug had an improperly crimped power wire that charred and melted the plug. I dissected the plug to see what happened and it was obvious the crimp was never properly done.
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Old 09-30-2019, 07:29 AM   #24
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Definitely and eye opener seeing the photos - thanks for posting them. We had a hardwired 50a unit in the prior trailer and never did like the constant humming. I’d remove the cover annually to inspect connections and never found a loose lug. I went with a portable unit this time.
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Old 10-05-2019, 12:52 PM   #25
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Not to hijack but I now want to inspect my Progressive unit wiring. I'm DIY challenged so have to ask, this problem is all installation related and nothing to do with the unit itself?
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Old 10-05-2019, 02:10 PM   #26
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We hard wired the same unit and it failed...never hard wire again
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https://www.jaycoowners.com/forums/m...albums843.html Check this out.
https://www.jaycoowners.com/forums/f...s-34672-3.html
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Old 10-05-2019, 06:54 PM   #27
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Chaffing of wires is a great concern in RV's. I see wires wrapping around metal edging with out any protection. Its just a matter of time from all the bouncing around that these wires will loose the insulation & short out. Again its the industries poor standards that allows these manufacturers to get away with this.
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Old 10-05-2019, 09:26 PM   #28
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Not to hijack but I now want to inspect my Progressive unit wiring. I'm DIY challenged so have to ask, this problem is all installation related and nothing to do with the unit itself?
Itís a little of both. Itís the sharp edge on that pass through sensor that slowly knifes itís way into the wire next to it. Given the chance to do it again, Iíd strip the wires longer and somehow route the wires so the sharp edge couldnít touch the adjacent wire. It never crossed my mind 3 years ago as an issue that could happen and it wasnít stated in the directions to do so.

Even if it wasnít the cause as some people keep insisting, itís still worth a look to be sure.
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Old 10-05-2019, 09:44 PM   #29
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Keep us informed on your warranty claim with Progressive. Hopefully they'll be on your side.
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Old 10-08-2019, 12:43 PM   #30
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Screwby, Thanks for the post!

I will be interested in what Progressive has to say. I too agree with most that the lug was not tight and the heat and melting started at the lug. You can see by your picture that the heat was more intense at the lug.
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