That's what I am thinking. And the IQ7+ max current is actually about 2%
higher than rated and we have a 1.3x DC to AC ratio so I would not be
surprised if all microinverters are completely maxed out for brief periods
at peak sun.

I'm working on getting pictures from one of my tech's phones. I think we
have one of the discolored wire.





On Wed, Nov 18, 2020 at 4:16 PM Dave Tedeyan <[email protected]> wrote:

> Jason,
> Bright sunny days, disconnect on the west side of house, maybe in the sun?
> 43.56A * 1.25 for continuous duty = 54.45A. If these disconnects are also
> baking in the sun, maybe the extra ambient heat is enough to push it over
> the edge? Just a thought.
> Cheers,
> Dave
>
> *Dave Tedeyan, PE*
> Senior Engineer | Taitem Engineering, PC
>
> 110 South Albany Street | Ithaca, NY 14850
> o. *607.277.1118 x121*  f. 607.277.2119
> www.taitem.com
> <https://mailtrack.io/trace/link/f4542e8acedc3d46e0c318320bdeecbb0abd9c2e?url=http%3A%2F%2Fwww.taitem.com&userId=1613865&signature=1fe5f11e2f248f42>
>
> Solar • Sustainability • Energy • Design
> Certified B-Corporation since 2013
>
>
> On Wed, Nov 18, 2020 at 3:41 PM Jay <[email protected]> wrote:
>
>> Hi Jason
>>
>> Any chance for some photos?
>>
>> Jay
>>
>> On Nov 18, 2020, at 12:18 PM, Jason Szumlanski <
>> [email protected]> wrote:
>>
>> 
>> The plot thickens on the fuse blowing issue. Again, we tore the Enphase
>> IQ system apart looking for any reason for the fuse to keep blowing. We
>> reconfirmed torque on all line side conductors to the service (supply side
>> interconnection using Polaris taps).
>>
>> Low and behold, I get a second client with the exact same issue
>> yesterday. The circumstances are eerily alike. Both disconnects are located
>> on the west side of the house and have 36 IQ7+ microinverters on an IQ
>> Combiner, requiring 60A fuses on the 60A fusible disconnect. The combined
>> inverter output rating is 43.56A. The interconnections are identical with
>> #6 THHN 90ºC conductors and Polaris taps. Both disconnects have conductors
>> on the right-hand side line-side terminal that are discolored (the copper
>> is silvery, the insulation is not burned). The fuses blow at peak current
>> around 1:30 pm, only on bright and sunny days.
>>
>> I'm starting to suspect a faulty fusible disconnect switch. Maybe the
>> blades are not making proper contact with the line side terminals.
>>
>> For the client who is having regular/frequent fuses blowing I plan to
>> replace the disconnect with a heavy-duty version or possibly get a 100A
>> disconnect with fuse reducers. I'm not sure which option would yield a
>> better test. I might also switch brands.
>>
>> Currently, we are using GE TG3222R. The fuses are Bussman FRN-R Time
>> Delay. I have to believe a heavy-duty switch would be less susceptible to
>> this, but maybe a higher rated one would be a better option. I'm not a fan
>> of fuse reducers, however.
>>
>> Jason Szumlanski
>> Florida Solar Design Group
>>
>>
>> On Sun, Aug 30, 2020 at 5:54 PM Jason Szumlanski <
>> [email protected]> wrote:
>>
>>> The tripping breaker occurred at random times, even at night. No
>>> weather-related correlation.
>>>
>>> I have more research to do to see when this fuse issue is happening, but
>>> previous visits showed no water ingress. I'm not sure about temperature.
>>>
>>>
>>>
>>>
>>> On Thu, Aug 27, 2020 at 8:51 PM Jay <[email protected]> wrote:
>>>
>>>> Hi Jason
>>>>
>>>> One thought I have about the blowing fuse is to check it with a IR
>>>> tool.
>>>>
>>>> I suspect a poor connection of the fuse to holder which during higher
>>>> air temp is causing it to fail.
>>>> I’m assuming that the correct amp size and slow blow fuse Is installed
>>>> and that the wire connections are done correctly. But again an IR tool
>>>> during peak heat would be  a good test.
>>>>
>>>> About the enphase fix, wow what a head scratcher. But given that it’s
>>>> fixed it means that it’s not a short, but enough amps going through over
>>>> enough time to trip it. I wonder if a magnetic hydraulic vs thermal breaker
>>>> ( CBI  vs CH etc) would have worked?
>>>>
>>>> Is that breaker box ever in the sun?  Is there any Correlation between
>>>>  high ambient temperatures and tripping?
>>>>
>>>> It sure would keep me up at night too
>>>>
>>>> Jay
>>>>
>>>>
>>>> On Aug 27, 2020, at 4:29 PM, Jason Szumlanski <
>>>> [email protected]> wrote:
>>>>
>>>> 
>>>> So the resolution to this is in... But I still have no idea what was
>>>> wrong.
>>>>
>>>> The string of 10 offending microinverters was split into 5 and 5. We
>>>> had a spare breaker in the IQ Combiner so it was relatively easy to run
>>>> another branch circuit. It has been over two months with no recurrence. So
>>>> the issue seems to be resolved, but again, no idea why.
>>>>
>>>> So here we go again... On another system we have a similar problem now.
>>>> In this case it is supply side interconnected with a fusible disconnect.
>>>> The same fuse (same line) keeps blowing every few to several weeks. We
>>>> can't find any home run wiring issues or issues with terminator caps. There
>>>> are no apparent faults in the AC Combiner. We have no idea why this is
>>>> happening. But in this system, just the fuse blows, not one of the
>>>> individual branch circuit breakers.
>>>>
>>>> This is getting very frustrating. And this is way more serious because
>>>> fuses and service calls are expensive and I can't isolate the issue to one
>>>> branch circuit. I don't even know where to start. Leaving each circuit
>>>> disconnected for several weeks to prove a negative is an untenable
>>>> suggestion to make to a client. But I don't see any other good options.
>>>>
>>>> Jason Szumlanski
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>>
>>>> On Tue, Jun 9, 2020, 3:42 PM Jason Szumlanski <
>>>> [email protected]> wrote:
>>>>
>>>>> Yes, we double-checked that. I have seen that happen before and it's
>>>>> one of my early diagnostic steps for something like this.
>>>>>
>>>>>
>>>>>
>>>>>
>>>>> On Tue, Jun 9, 2020 at 9:18 AM Mac Lewis <[email protected]> wrote:
>>>>>
>>>>>> Hi Jason,
>>>>>>
>>>>>> Are you certain that the branch circuits aren't crisscrossed
>>>>>> somewhere, meaning that an L1 branch 1, isn't connected to an L2 branch 
>>>>>> 2?
>>>>>> That could explain two different breakers tripping.
>>>>>>
>>>>>> Good luck
>>>>>>
>>>>>>
>>>>>> On Wed, Jun 3, 2020 at 1:07 PM Jason Szumlanski <
>>>>>> [email protected]> wrote:
>>>>>>
>>>>>>> Undoubtedly, the termination caps are the second thing we check
>>>>>>> after the rooftop junction box(es). These are prone to installation 
>>>>>>> errors,
>>>>>>> even when the right parts are used. And given the cost, I've thought 
>>>>>>> very
>>>>>>> long and hard about abandoning them altogether and terminating strings 
>>>>>>> in
>>>>>>> small j-boxes with watertight fittings. But in this case, there was no
>>>>>>> evidence of improper installation (we replaced them) and it was not
>>>>>>> correlated to rain events.
>>>>>>>
>>>>>>> We are well equipped with bare Q-cable and field wireables that we
>>>>>>> could use for troubleshooting to bypass certain sections, but the
>>>>>>> intermittent nature of the problem and unpredictable timeframe between
>>>>>>> faults is very frustrating. While this is a rare occurrence, it is
>>>>>>> definitely a "con" to consider when comparing string vs. microinverters
>>>>>>> that I had not strongly considered in the past. I'm intent on getting to
>>>>>>> the bottom of this in order to learn what to look for in the future and 
>>>>>>> how
>>>>>>> to approach diagnoses of Enphase branch circuit faults.
>>>>>>>
>>>>>>> Jason
>>>>>>>
>>>>>>>
>>>>>>>
>>>>>>>
>>>>>>>
>>>>>>> On Wed, Jun 3, 2020 at 2:31 PM Amos Post <
>>>>>>> [email protected]> wrote:
>>>>>>>
>>>>>>>> I was just at a site last week where the Enphase branch circuit
>>>>>>>> breaker, outside utility disconnect breaker, and feed breaker in the 
>>>>>>>> main
>>>>>>>> panel all tripped simultaneously, and it happened about 1 hour before I
>>>>>>>> showed up onsite.  The customer said it had happened 1 other time last 
>>>>>>>> fall
>>>>>>>> but that time it was just the 1 branch circuit in the Enphase combiner
>>>>>>>> panel.  Interestingly the customer mentioned that he had just washed 
>>>>>>>> off
>>>>>>>> the panels, also about 1 hour before I got there.  I went on the roof 
>>>>>>>> and
>>>>>>>> found that the installing contractor had not put on the Enphase 
>>>>>>>> termination
>>>>>>>> caps.  1 string was wire-nutted with regular wire nuts and sitting on 
>>>>>>>> the
>>>>>>>> roof, and the roof was damp right there. This was a fairly flat roof.  
>>>>>>>> The
>>>>>>>> other micro trunk cable was just cut with no protection at all, tied 
>>>>>>>> to the
>>>>>>>> rail…
>>>>>>>>
>>>>>>>>
>>>>>>>> <IE LOGO 150x78.jpg>
>>>>>>>>
>>>>>>>>
>>>>>>>>        Amos Post
>>>>>>>>    Integrity Energy
>>>>>>>>   W 802.763.7023
>>>>>>>>    C 802.291.2188
>>>>>>>>     ienergyVT.com
>>>>>>>> <https://mailtrack.io/trace/link/78588842d30cdf5fdc6d390748c63c8f3f9c7a2c?url=http%3A%2F%2Fwww.ienergyvt.com&userId=1613865&signature=8bfa0b8ba517bffd>
>>>>>>>>         Facebook
>>>>>>>> <https://mailtrack.io/trace/link/896240f1536f22e23ddee704c5ba83dccc073ef6?url=https%3A%2F%2Fwww.facebook.com%2Fintegrityenergyllp%3Fref%3Dhl&userId=1613865&signature=d30adae4a99721e9>
>>>>>>>>
>>>>>>>> On Jun 3, 2020, at 2:05 PM, Jason Szumlanski <
>>>>>>>> [email protected]> wrote:
>>>>>>>>
>>>>>>>> The breaker in the main panel IS tripping simultaneously with one
>>>>>>>> of the branch circuit breakers each time.
>>>>>>>>
>>>>>>>>
>>>>>>>>
>>>>>>>>
>>>>>>>>
>>>>>>>>
>>>>>>>> On Wed, Jun 3, 2020 at 12:43 PM Jay <[email protected]> wrote:
>>>>>>>>
>>>>>>>>> A question that keeps nagging me is why do these breakers trip and
>>>>>>>>> not the breaker in the main panel?
>>>>>>>>> Presuming there is a 40 amp in the main
>>>>>>>>>
>>>>>>>>> I would have thought that given all the times the breakers have
>>>>>>>>> tripped at some point that one would have tripped and I can’t 
>>>>>>>>> understand
>>>>>>>>> why not?
>>>>>>>>>
>>>>>>>>> Jay
>>>>>>>>>
>>>>>>>>> On Jun 3, 2020, at 8:27 AM, Jerry Shafer <[email protected]>
>>>>>>>>> wrote:
>>>>>>>>>
>>>>>>>>> 
>>>>>>>>> Wrenches
>>>>>>>>> Looking g at the bigger breaker tripping at the same time is very
>>>>>>>>> likely do to response time of the breaker nothing more. As l 
>>>>>>>>> suggested in a
>>>>>>>>> previous message. Use a non bridged breaker to see if it is one or 
>>>>>>>>> both
>>>>>>>>> legs that trip. Also an eguage will help to see what if anything 
>>>>>>>>> leads up
>>>>>>>>> to the failure and when.
>>>>>>>>> Jerry
>>>>>>>>> Jerry
>>>>>>>>>
>>>>>>>>> On Wed, Jun 3, 2020, 7:58 AM Jason Szumlanski <
>>>>>>>>> [email protected]> wrote:
>>>>>>>>>
>>>>>>>>>> I wonder about that. Of course, it could be the "inverter output
>>>>>>>>>> circuit" having a fault in the wiring still (an intermittent issue
>>>>>>>>>> somewhere within the IQ cable or home run wiring). But internal to 
>>>>>>>>>> the
>>>>>>>>>> microinverter, is it possible that a fault could still occur at 
>>>>>>>>>> night? I
>>>>>>>>>> had a suggestion from another wrench that there are film capacitors 
>>>>>>>>>> on the
>>>>>>>>>> AC output side, but are these isolated when there is no DC input? It 
>>>>>>>>>> seems
>>>>>>>>>> unlikely that this would be an issue, but I have seen microinverters
>>>>>>>>>> reporting a couple of watts at night (in Enlighten). I'm not sure 
>>>>>>>>>> how real
>>>>>>>>>> that is.
>>>>>>>>>>
>>>>>>>>>> The overriding question I have is what kind of fault would cause
>>>>>>>>>> BOTH a branch circuit and the main solar breaker to trip 
>>>>>>>>>> simultaneously?
>>>>>>>>>> That seems odd to me. If any normal load branch circuit has a fault, 
>>>>>>>>>> you
>>>>>>>>>> don't often see premises main breakers tripping, or even feeder 
>>>>>>>>>> circuit
>>>>>>>>>> breakers.
>>>>>>>>>>
>>>>>>>>>> I got to thinking that maybe there is some kind of issue between
>>>>>>>>>> the BR220 and CH240 breakers not playing nicely together. But I 
>>>>>>>>>> would think
>>>>>>>>>> this would be a well-known issue because I'm sure there are tons of 
>>>>>>>>>> CH
>>>>>>>>>> feeder breakers in the wild with BR branch circuits downstream.
>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>> On Tue, Jun 2, 2020 at 9:25 AM <
>>>>>>>>>> [email protected]> wrote:
>>>>>>>>>>
>>>>>>>>>>> If it trips at night, we know it is not the output from the
>>>>>>>>>>> inverters causing the tripping. The current must be coming from the 
>>>>>>>>>>> grid.
>>>>>>>>>>> ---
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>> On 2020-06-01 12:05, Jason Szumlanski wrote:
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>> It's not weather. It's at all times of the day and night, and I
>>>>>>>>>>> confirmed that there is no correlation to rain or high winds. That 
>>>>>>>>>>> was my
>>>>>>>>>>> first suspicion.
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>> On Mon, Jun 1, 2020 at 10:27 AM Ray <[email protected]> wrote:
>>>>>>>>>>>
>>>>>>>>>>> Is it at all weather related?  Rain, or high humidity?  High
>>>>>>>>>>> temperatures?  Do you have any indication what time of day it trips 
>>>>>>>>>>> off at?
>>>>>>>>>>>
>>>>>>>>>>> Ray Walters
>>>>>>>>>>> Remote Solar
>>>>>>>>>>> 303 505-8760
>>>>>>>>>>>
>>>>>>>>>>> On 6/1/20 10:23 AM, Jason Szumlanski wrote:
>>>>>>>>>>>
>>>>>>>>>>> Well, that didn't resolve it. The main breaker and a branch
>>>>>>>>>>> circuit breaker tripped again a few days ago. It was the same 
>>>>>>>>>>> branch this
>>>>>>>>>>> time.
>>>>>>>>>>>
>>>>>>>>>>> As my next diagnostic step I swapped two circuits (on which
>>>>>>>>>>> breaker they are landed). If history is a guide, it will work for 
>>>>>>>>>>> about two
>>>>>>>>>>> weeks and then trip again.
>>>>>>>>>>>
>>>>>>>>>>> I'm dumbfounded. I really don't want to have to tear this whole
>>>>>>>>>>> system apart. At this point, if I have to remove all the modules, I 
>>>>>>>>>>> feel
>>>>>>>>>>> that I need to replace all of the trunk cable which is an expensive
>>>>>>>>>>> proposition. I really don't know what else to do at this point.
>>>>>>>>>>>
>>>>>>>>>>> Jason
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>> On Mon, May 25, 2020, 10:43 AM Jason Szumlanski <
>>>>>>>>>>> [email protected]> wrote:
>>>>>>>>>>>
>>>>>>>>>>> I strongly suspect the CH240 combined breaker was compromised
>>>>>>>>>>> (we will see). Since it happened that two different strings 
>>>>>>>>>>> tripped, I
>>>>>>>>>>> doubt I have two microinverters with internal faults. It has to be 
>>>>>>>>>>> the
>>>>>>>>>>> combined breaker. I was just surprised that branch circuit breakers 
>>>>>>>>>>> were
>>>>>>>>>>> tripping simultaneously with the combined output breaker.
>>>>>>>>>>>
>>>>>>>>>>> Of all the supply side connected systems I have installed, I
>>>>>>>>>>> have never seen a combined output fusible disconnect fuse blow, but 
>>>>>>>>>>> I have
>>>>>>>>>>> seen many combined output breakers tripped. I was worried early on 
>>>>>>>>>>> that I
>>>>>>>>>>> would be replacing fuses constantly, but that has not been an issue
>>>>>>>>>>> whatsoever.
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>> On Thu, May 21, 2020 at 11:15 AM <[email protected]>
>>>>>>>>>>> wrote:
>>>>>>>>>>>
>>>>>>>>>>> Actually, we had a IQ7 string loaded up to its max panel size
>>>>>>>>>>> and max string length and in the spring on cool, clear day, it 
>>>>>>>>>>> tripped the
>>>>>>>>>>> string's associated breaker in the Enphase combiner.
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>> We reset but of course that breaker was impaired and it tripped
>>>>>>>>>>> again. We replaced and never had an issue going forward. We suspect 
>>>>>>>>>>> the
>>>>>>>>>>> breaker was less than perfect from the start as we've add equally 
>>>>>>>>>>> nice days
>>>>>>>>>>> since.
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>> This almost reminds me of loading up Outback FM80. It says 4,000
>>>>>>>>>>> watts but in reality, 3,600 is the max when amps spike. I will be 
>>>>>>>>>>> extra
>>>>>>>>>>> careful going forward on IQ7 string length when going to the max
>>>>>>>>>>> published...
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>> My story.
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>> Scot
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>> *From:* RE-wrenches <[email protected]> *On
>>>>>>>>>>> Behalf Of *Jason Szumlanski
>>>>>>>>>>> *Sent:* Thursday, May 21, 2020 8:57 AM
>>>>>>>>>>> *To:* RE-wrenches <[email protected]>
>>>>>>>>>>> *Subject:* [RE-wrenches] Enphase intermittent breaker trippjng
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>> I'm trying to resolve an intermittent frustrating problem with
>>>>>>>>>>> and Enphase IQ system. There are three AC Branch circuits of 9
>>>>>>>>>>> microinverters each coming into an Enphase AC combiner.
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>> What has been happening is one of the BR220 branch circuit
>>>>>>>>>>> breakers and the combine CH240 breaker in the main backfed load 
>>>>>>>>>>> center have
>>>>>>>>>>> been tripping simultaneously. It has happened about four times in 
>>>>>>>>>>> the last
>>>>>>>>>>> 6 months. It was always the same branch circuit breaker, so we kept
>>>>>>>>>>> investigating that string, checking the junction box, trunk cable, 
>>>>>>>>>>> and cap,
>>>>>>>>>>> etc. Finally we swapped out the BR220 breaker.
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>> Fast forward 4 weeks, and we got another call. This time a
>>>>>>>>>>> different branch circuit breaker and the main breaker tripped
>>>>>>>>>>> simultaneously. We checked that branch circuit and could not find 
>>>>>>>>>>> any
>>>>>>>>>>> fault. It seems unlikely that two branch circuit breakers would be 
>>>>>>>>>>> faulty,
>>>>>>>>>>> so we have now switched out the CH240 main breaker in hopes that it 
>>>>>>>>>>> is the
>>>>>>>>>>> culprit.
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>> I'm not totally confident in this resolution and I have my
>>>>>>>>>>> fingers crossed. If that doesn't work, does anyone have any 
>>>>>>>>>>> suggestions on
>>>>>>>>>>> another diagnostic step? These intermittent problems are a major 
>>>>>>>>>>> hassle.
>>>>>>>>>>> One thought I had was to switch to a supply side interconnection 
>>>>>>>>>>> with a
>>>>>>>>>>> fusible disconnect. Maybe the intermittent fault would blow one of 
>>>>>>>>>>> the two
>>>>>>>>>>> line fuses so at least I could narrow it down to which line the 
>>>>>>>>>>> fault is on
>>>>>>>>>>> if there is in fact a fault.
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>> I have experienced two other tripping breaker issues with
>>>>>>>>>>> Enphase systems in the past. Neither of them were systems I 
>>>>>>>>>>> installed. One
>>>>>>>>>>> turned out to be branch circuits that were not properly paired up 
>>>>>>>>>>> and
>>>>>>>>>>> landed on different breakers. Another time we had an inverter with 
>>>>>>>>>>> an
>>>>>>>>>>> internal fault which eventually"blew up" with a loud popping noise 
>>>>>>>>>>> and
>>>>>>>>>>> smoke billowing out of it. That happened after resetting a trip 
>>>>>>>>>>> breaker
>>>>>>>>>>> multiple times. This case seems to be unrelated to those issues. I'm
>>>>>>>>>>> perplexed.
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>> Jason Szumlanski
>>>>>>>>>>>
>>>>>>>>>>> Florida Solar Design Group
>>>>>>>>>>>
>>>>>>>>>>>
>>>>>>>>>>> _______________________________________________
>>>>>>>>>>>
>>>>>>>>>>>
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