Solar Issue

[Tether]

I fought for over a year with an intermittent solar problem. It would work sometimes and then not and finally just quit. During that period I replace the controller and the solar panel. I traced all the wiring and pulled all my hair out. I finally found a loose pin the the cable entry on the roof. When the panel was connected it would push the pin back into the cable entry. Sometimes it would make a connection but then vibration as we rolled down the road would break the connection. When I pulled the panel connector out, tension in the cable or just friction of the connector would just slide the pin back into its proper location. Every time I tested for continuity with a meter or tone generator, I had continuity. I even fed 12 volts from the battery compartment back to the roof cable entry. Small issues can drive you nuts.

 

[Radar57]

As an aircraft mechanic we occasionally run into the same type issue. Not necessarily on new aircraft but it can and has occurred on one 4 or 5 years or older with several thousand hours. Intermittent issues, the worst kind. Troubleshoot, ring wires, pull and tug or wire bundles but can't get it to fail. Finally resort to pulling the connector apart and find a pushed pin or bad crimp. Very frustrating. Glad you found the source of your troubles.