Tesla Solar Roof + Powerwall Electrical Saga

[iorchii]

Right before we were leaving for a friend's destination wedding, we plugged in our car but the Tesla Wall charger did not work. Not enough time to troubleshoot as we needed to head to the airport.
Arriving home with the EV on its last leg with a few miles of range, we put in a Tesla Solar support request but decided to call our electrician since our house experienced 3 outages while we were gone.
Electrician found this doozy done by Tesla Solar electricians tucked right behind our main disconnect which explains the outage & why our Tesla Wall charger stopped working.
Still waiting for Tesla Solar support to respond...

 

[ptdusn]

Very lucky you didn't have an electrical fire take your house with it.

 

[GlmnAlyAirCar]

I wonder what the inspector had to say….

 

[iorchii]

I wonder what the inspector had to say….

We received PTO late November 2021 with all permits approved. But I guess they never caught this.

 

[Eric99]

Do you know what wires those go to? Looks like there is a fair amount of corrosion and could be old work?

 

[BGbreeder]

Corrosion, plus a missing wire nut insulator, plus what looks like smoke residue on the yellow (white?) wire...

I hope that whatever it is, it isn't connected to power.

All the best,

BG

 

[yblaser]

I assume all the visible issues were a result of the overheating of the splice. You would have to take off what remains of the wire nut to see what led to the high resistance splice.

 

[FurryOne]

There shouldn't have been splices in the first place. If they cut the wires too short they should have moved a few of the lower breakers to be able to put the 50/60A breaker lower in the box and eliminate the need for splices. Ugh! Not only that, but they shouldn't have used wire nuts for that kind of amperage.

 

[patrick40363]

Right before we were leaving for a friend's destination wedding, we plugged in our car but the Tesla Wall charger did not work. Not enough time to troubleshoot as we needed to head to the airport.
Arriving home with the EV on its last leg with a few miles of range, we put in a Tesla Solar support request but decided to call our electrician since our house experienced 3 outages while we were gone.
Electrician found this doozy done by Tesla Solar electricians tucked right behind our main disconnect which explains the outage & why our Tesla Wall charger stopped working.
Still waiting for Tesla Solar support to respond...
View attachment 854104

Where are you located?

 

[iorchii]

Do you know what wires those go to? Looks like there is a fair amount of corrosion and could be old work?

Wires were for Tesla wall charger, they were new wires added by Tesla to the Backup Load Center.

 

[iorchii]

There shouldn't have been splices in the first place. If they cut the wires too short they should have moved a few of the lower breakers to be able to put the 50/60A breaker lower in the box and eliminate the need for splices. Ugh! Not only that, but they shouldn't have used wire nuts for that kind of amperage.

Previously one set of the wires were directly tucked behind the main disconnect without a wire nut, I assume each time we used the charger the heat generated cause what you see was a white melted wire.
Tesla electrician finally came out after a week & a half from my support request. All they did was tucking it between the wires with wire nut & electrical tape.

 

[iorchii]

Where are you located?

Southern California

Corrosion, plus a missing wire nut insulator, plus what looks like smoke residue on the yellow (white?) wire...

I hope that whatever it is, it isn't connected to power.

All the best,

BG

Yes white wire & correct there was a mild smoke smell because of the melted wire.

I assume all the visible issues were a result of the overheating of the splice. You would have to take off what remains of the wire nut to see what led to the high resistance splice.

Yup overheating when charging at 48A, Tesla electrician cut the damaged portion, wire nut & added electrical tape then tucked it in between the wires instead of behind the main disconnect breaker. All the breakers were rerouted to our Backup Load center.

 

[Eric99]

Am i missing something? To charge at 48A you need a 60A breaker AND respective wiring, 4AWG (copper). The 40A breaker should have tripped to protect the wires, which look suspiciously small (sorry, i cant tell from looking).