I need some help. A customer purchased his own Kestrel turbine and controller. Asked me to wire it into his existing off grid system.

I did so per the manufacturers instructions and the controller works for about a week and the quits. The homeowner gets a second controller and changes it out (thinking we had a bad controller), same thing. After some troubleshooting and talking to the techs. at Kestrel, we decided to "clean up" the DC side of this customers system. I spent a day taking every connection apart and installing new breakers and wiring the way I like to do it. I did find some loose connections and some heated wires from loose connections. I thought we had figured it out with those bad connections, but no. A third controller worked for about a week.

His system consists of an Outback MX 60 charge controller for his 2000 watt solar array. He has a Xantrax mod. sine wave inverter. A couple of Exeltech inverters to individual circuits that require pure sine wave power. He also has a generac propane generator.

I haven't spent much time troubleshooting this system other than rewiring the Dc side and checking that equipment grounds are all connected at one spot. I guess I will really need to dig into it for him and was hoping someone out there would have seen this problem and it is a simple fix that we have just overlooked.

If you need more info about the system I will need to go up there to see because I did not supply any of his equipment.

Any help would be appreciated. Thanks!