Would you believe I did check the internal fuse on the multimeter. It worried me that the only reading while on the 10A scale (and plugged into the 10A connector) was 0.00, so my initial thoughts where a failed internal fuse on the multimeter. I was reluctant to try the lower scales on the multimeter as that connector has a 0.2A limit.
Anyway, I opened up the multimeter and the internal fuse was fine, and was confirmed with a continuity check. It was now that I thought it was safe to swap the positive connection on the multimeter and try the lower scales.
On the photo above, the multimeter is set to read mA and is indicating 1.7mA, which would confirm a 10A reading of 0.00, and so I believe the multimeter is correct and working fine. Also confirmed by the 5w bulb crashing the voltage.
Therefore, the current at the silver tinny strips (foil leadouts) before the PCB is tiny. However, tomorrow in the sunlight I will check again with a 5w bulb across the tinny strips (foil leadout) just to confirm your idea.
Thanks anyway for the continued ideas. I am willing to try anything to find out what's wrong with this solar panel.
I connected a 5w bulb across the silver tinny strips (foil leadouts) before the PCB and not even glimmer. I also watched the voltage across the strips as I connected the bulb and it went from 21v to 0.01v.
All this was in bright, hot, blue sky sunshine, with the panel directed towards and flat against the sun direction.
Sorry mate, but I think the fault lies upstream of the tinny strips (foil leadouts)
I do realise that people who have a technical bent, and who have helped, do like to find out the final solution. Furthermore, a problem and solution shared, might help someone else one day. I do know and understand what you are feeling, as I too have searched this forum many a time for an answer to something, only to find a similar question with some half answers but not the final solution.
Anyway, I finally sorted this about 3 weeks ago, but I have had very little time to complete this tale as I've very busy at work recently. I'm even compiling this whilst away with work in Jamaica.
So, to cut a long story short........ we've seen from the previous posts on this thread that we eventually got the panel off the motorhome and confirmed it was not giving any significant current.
As expected, Brownhills Newark who fitted the panel were useless and did not return any calls. But, after inspecting their workmanship in fitting the original panel that is probably a blessing.
Roadpro, who were the original importers, said they could not help as they were no longer Alden importers of solar panels and had no spares.
So I called the current Alden UK importer, Eddie from Vanbitz, who was very helpful but could not offer direct support as I did not purchase the panel from him. Although, he did say that if I got no joy from Alden direct then to contact him again and he would see what he could do to help.
However, this has not been required as Alden in France have been excellent. Claire is a Star!!!
I rang the phone number provided by Patrick_Phillips earlier in the thread, and Clair answered (in French). However, as soon as I spoke English, a perfect English voice came back, and I explained my problem. She then past me onto Sabastien, their technical guy, and he eventually asked if I could send the panel and the Alden SPS110 regulator to them.
Well, even though I knew it would be expensive to sent a large 10kg solar panel to France, I said yes, knowing I needed all the help I could find. After multiple telephone calls to many couriers, most over £100, I ended up using Fedex (£70, fully tracked) to send the panel to:-
ALDEN
14 Route de Strasbourg
67230
HUTTENHEIM
A week later, I rang Claire and she said she was very sorry but they had been unable to test the panel yet, but that it had arrived undamaged. No problem I said, I would call them again in another week.
Anyway, a few days later she called back to say they had tested my panel and could confirm, for some unknown reason, it was dead. She informed me that they had never seen a panel behave like this before and that it had many at Alden scratching their heads. However, as they had been able to confirm the panel was dead, she would like to replace the panel for new. Wow, customer service......it will never catch on.
........and, it got better, she would also like to included a fixture kit to help me refit the panel. I was very grateful.
4 days later DHL pulled up and delivered a large package direct from Alden. I opened it and found a new 85w panel, my original regulator, 4m of Alden black cable, 4m of Alden blue cable, a new roof/cable faring, fitting instructions, a tube of Sikaflex and a bottle of sikaflex activator and applicator. Wow!! This was going to be hugely helpful.
It took another 2 weeks before I got the opportunity to fit the new panel.
So, whilst on the roof I took the time to inspect the Brownhills workmanship. I felt this was required due to the wiring that I had found under the van. What I found was concerning, and sorry to say, not surprising for Brownhills.(Why oh why are they still in business)
I had noted that the wire into this cable trunking was black, but on exiting it was blue:-
so, I opened it, and found another soaking wet soldered joint !?!?!?!:-
I am wondering if these multiple soldered, and wet, wiring joints had any bearing on the panel failure?????
So...With this in mind I felt the entire wiring had to be replaced. Luckily for me Alden had supplied new cable, so I decided to use it and rewire the whole installation, exactly in accordance with the supplied instructions. This meant using the thick Alden black cable to bring the solar panel electrical output in through the roof in a single run, and then to use a dry cable connector onto the 4mm2 Alden blue cable to route to the regulator.
The original wiring came in through the roof ran down the inside of the van and then out through a hole drilled in the floor. Across under the van and then forward until under the drivers seat. Then back up through the hand-brake cable hole and into the Alden regulator next to the EBL99 control unit. I noted that as the electrical cable came up through the handbrake cable hole that the sealing grommet was just push up the steel cable out of the hole and out of the way. This left the electrical cable rubbing between bare metal and the handbrake steel cable.
Add this to the 3 soaking wet soldered joints and I'm amazed the whole thing didn't cause a fire. In other words, an appalling job with shoddy workmanship yet again from the cowboys at Brownhills Newark!!!
Furthermore, after I released the sealing nut on the cable/roof faring, and as I eased the cable down and through the roof/cable faring, I noted that water began dripping into the van, although the van roof was dry and it wasn't raining. This was confusing so I decided to break the seal and remove the roof/cable faring. Yet again, I found more shoddy workmanship. The photo below shows that the leading edge of the sealant was not complete and was full of holes. This allowed water to fill inside the faring and then remain there. What is difficult to see on the photo, is that within the sealant boundary, is a puddle of water. The underside of the faring is also wet and the only thing stopping the puddle draining completely into the van was the small amount of silicon sealant on the hole itself.
So, not only was I replacing the solar panel and all the wiring, I was now also replacing this faring. Luckily, and thanks to Alden, we had a new one to use.
I eventually finished this job by removing all the old Sikaflex, re-glueing the solar panel onto the roof and changing the cable run. The cable run is no longer under the van, but now runs through the inside. I now have a single run of Alden black cable, in through the roof (new faring and sealed properly) and then though the inside structure and into a cable box. Its then connected onto the Alden 4mm2 blue cable and run though the inside to behind the front passenger seat, then into the proper floor cable run and across to the regulator under the drivers seat. In all, about 2.5m less cable run and only one joint, exactly as per the Alden instructions. I then filled the holes through the floor left from the original wiring with rubberised jointing compound.
I have noticed that the panel is now working brilliantly. I had never seen more than 1A from the panel previously and always just put this down to poor sun light. I now see it give over 3A in dull sunlight.......wow.....what a difference. I imagine in bright sunlight and with us using the batteries, I will see it giving over 4.5A-5A.
This job would not have been possible without the support of Alden and Claire. I owe them a lot of gratitude and thanks, as I could not have afforded to replace the panel at my expense. This has firmly placed Alden onto my list of trusted and decent motohome companies, and as we all know, that is not a big list. WELL DONE ALDEN!
A happy ending thanks to outstanding proactive customer support and I hope a little help from your MHF friends
______________________________________________________________ Regards Frank
RIP Peter Our thoughts are with you Chris. Fighting with Mavis and Ray and a wee wave for Fiona
Get behind early - it gives you more time to catch up.
Denn wir haben nichts in die Welt gebracht; darum offenbar ist, wir werden auch nichts hinausbringen.
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WELL DONE ALDEN!
Our thoughts are with you Chris. Fighting with Mavis and Ray 
and a wee wave for Fiona 
