Charge Controller Melting Inside? Here's What's Happening

I nearly lost my solar setup when my Renogy Rego 60A MPPT charge controller started melting internally. After doubling my solar array, I discovered a dangerous heat issue caused by a mismatched internal connector. In this video, I tear down the Renogy Rego to show you exactly what failed (the internal Anderson connector), why the factory wiring might be undersized for 60A continuous use, and the two modifications I made to fix it permanently: upgrading the connector and adding active cooling. Video Chapters: 00:00 - The Failure: Why my MPPT stopped working 01:52 - Teardown: Finding the melted connector 03:15 - The Design Flaw (8AWG vs 6AWG mismatch?) 04:24 - The Fix: Swapping the Anderson connector 06:30 - Mod: Adding a cooling fan for safety 07:59 - Stress Test: 145°F vs 89°F results As an Amazon Associate I may earn from qualifying purchases at no extra cost to you. Dr.Prepare 1,4000 BTU Smart WiFi Portable Air Conditioner https://amzn.to/3Tea5L9 Use code DIYHOME to save $ here: https://renogy.sjv.io/QOdxrP NEW 3000W 12V Pro Pure Sine Wave Inverter with EcoSleep Mode https://renogy.sjv.io/WyNXPX REGO 12V 400Ah Lithium Iron Phosphate Battery w/ Renogy ONE https://renogy.sjv.io/5gaavn REGO 12V 60A MPPT Solar Charge Controller https://renogy.sjv.io/AW00vR Top videos you need to see: Is the Renogy 3000W Inverter Worth It? https://youtu.be/QMby8O7ZFAs The Future of Solar: Renogy's 200W Anti-Shading Panel https://youtu.be/hwcAWoQkZfQ Explore the Power: NEW Renogy REGO Off Grid Solar System with Epic Battery Storage! https://youtu.be/CwL5dWB3kOQ DON'T FORGET TO LIKE COMMENT AND SUBSCRIBE https://www.youtube.com/channel/UClm4AsU5w3_509rlTMaGXbw?sub_confirmation=1 DIY Homestead Projects contact email - diyhomesteadprojects@yahoo.com WannaBFree Amazon affiliate link https://www.amazon.com/shop/wannabfree