We gathered the new parts yesterday and my friend said he woke up at 2:00 am and couldnt go back to sleep. I said it's because we are like kids waiting for Christmas morning. I was up at 4:00.
On top of the voltage drop that I was seeing I believe we weren't getting full power from one panel as one of the rusty screws in the combiner block had 10.50 volts.
We installed a new combiner box, 4 gauge all the way to the push button circuit breakers and all the way to the batteries. We had to piggy back cobble two pieces of 8 gauge together to form a temporary positive cable from the breaker to the battery until he goes to town.
We are advancing in finding our way through his 4 menu levels. It appears he is now putting out about 24.5 amps. I checked the voltage at the battery lugs on the controller and at the battery terminals and there is about .23 drop but as I said one cable is temporarily cheesy. I also installed a missing controller case ground cable. We also balanced the battery wiring and will finish up tomorrow. He is running his generator now to finish it off as he says the controller wont show battery full right away. We ran out of sun. It was still showing all dashes.
He said the only time he has ever seen that many amps is when charging with his magnum inverter charger. I'm trying to show him everything I can as we go through it and one item that was telling him something all along was the difference between the Blue Sky monitor and his magnum inverter remote panel. The B Sky would show 14.2 but the magnum was saying 13.4.
'
He's a great guy to work with because he's not cheap. We're not out to squander his money but it is what it is and it needs certain stuff to work right. $275 later it's seems to be working well. We improved on many wiring areas such as not having the cables zip tied to the frig coils! He's happy and said we are going to race again. :)