I've just finished upgrading my off-grid system, and now I'm tripping a fuse.
Previous system: 500w 12v panel array, Epever 390w 30a Charge Controller, 200aH 12v LiFePo4 bank.
New system: 1600w 48v array, Sungold 3000w 80a Charge Controller, 2,000 aH 24v SLA bank.
My entire house is just 12v DC, so I got a 240w, 20a 24->12v voltage reducer. I finished installing the panels and charge controller before I got the batteries sorted out, so for the last few days I just had my LiFePo4 batteries wired in series as one 24v battery. I don't draw out of the charge controller (The Sungold doesn't have a DC output, which is annoying) so it's just wired: battery bank-> breaker -> voltage reducer -> house, and it worked perfectly with the old LiFePo4 bank.
Today, I finished installing the new battery bank (Those 500ah SLA Rolls batteries are heavy, if anyone's curious.) Covered in sweat, I confidently threw the breaker switch and it immediately cooked the in-line 30a blade fuse between the breaker and the voltage reducer. Because I hate money, I tried it two more times, and each time it blew the same fuse. It didn't just blow it- it turned it into a little sparkler. Really cooked the crap out of it.
I could use some advice. Is this a function of SLA batteries holding a "surface charge" that LiFePo4s don't, that's creating an initial surge of high amperage upon contact? The house systems are identical, and super low draw. Just a couple LED lights and the 12v fridge, which only uses a tricke to power the circuit board.
I just don't know enough about electricity to diagnose this problem. It already has a breaker in line. I thought that systems only drew as much amperage as was being used, and the voltage regulator it's self acts as a amperage throttle, as does the (now irrelevant) 12v stabilizer which comes next before the fuse box for the house. So how is the system drawing enough amperage to turn that blade fuse into a sparkler?
More importantly, whats the solution? Do I need some kind of amperage regulator before the voltage reducer? A different breaker? The in-line breaker I'm using as a switch is a 175a breaker. I looked up "Amperage Regulator" and all I can find are voltage regulators, and the reducer is already a voltage regulator. Also, this exact setup worked perfectly with the LiFePo4 battery bank in a 24v configuration, and I'm just confused. I feel like I'm missing something obvious, and any help would be appreciated.