NHTSA Complaint #11422451 — 2021 JAYCO TRAVEL TRAILER JAY FLIGHT SLX

We bought a 2021 Jayco 224BHW that was pre-wired with a solar panel and controller. The trailer came with one 100-watt panel and a 30-amp charge controller with a stated capacity of 600 watts. We added two more 100-watt panels, for a total of 300 watts and approximately 16 amps. The documentation with the trailer as well as the dealer confirmed we could add two more 100-watt panels and be well within specifications. After utilizing the system for a few months the solar suddenly worked sporadically and then ceased too function. Upon inspection under the roof port entry it was discovered Jayco had utilized wire nuts between a transition from the roof port and the wire run to the solar controller. The wire nuts failed to adequately make or maintain the connection, resulting in arcing, melting, and burning of the surrounding insulation. It could easily have resulted in loss of the trailer or our lives to fire. I believe the wire nuts were either inadequately sized, improperly installed, or inappropriate for use in a structure that is subject to vibration and loosening of the connections.