6：Critical Reasons for a Solar Charge Controller Catching Fire and How to Ensure Safe Operation

There has been a problem that a solar charge controller catching fire with below situation

Three 100W panels, in a 12V battery system, could result in a maximum current of 25A-30A, which exceeds the rated current capacity of the controller. Prolonged operation under such conditions can easily lead to controller damage or overheating of connected components, causing unpredictable incidents.

Customer’s load equipment and power requirements.

Based on the customer’s feedback that “it seems to still work” and from the pictures provided, it appears that the outer casing is almost burnt, but the electronic components remain intact. Typically, burnt casing like this is caused by sparking or prolonged overheating.

Can the client provide pictures of the wiring terminals? Has there been any occurrence of long-term loose contact leading to sparking or burning within the controller?

The terminal posts and covers are made of flame-retardant material, with the cover melting at temperatures between 280 degrees Celsius, and the terminal posts melting between 260 and 350 degrees Celsius; they would not ignite even when exposed to a lighter flame. The outer casing, however, is made of non-flame retardant ABS plastic, with an ignition point between 300-320 degrees Celsius. From the images, it appears that the terminal posts have also been scorched, likely due to prolonged high temperatures.

To prevent solar charge controller fires, it’s crucial to focus on proper installation, using appropriate equipment, and regular maintenance. Here are key points to help prevent such incidents:

Use Certified Products: Ensure that the solar charge controller purchased and installed meet national standards. These devices have undergone rigorous safety tests, significantly reducing the risk of fire due to equipment failure.

Correct Installation Procedures: Have the system installed by professionals according to the manufacturer’s guidelines. Avoid electrical issues like short circuits during installation. Ensure all connections are secure and well-insulated to prevent loose or exposed wires from causing sparks.

Adequate Ventilation and Heat Dissipation: Install the solar controller in a location with good ventilation to ensure proper heat dissipation. Overheating is a major cause of fires, so maintaining airflow around the device is critical.

Regular Inspection and Maintenance: Periodically inspect the solar system, especially the electrical connections, for signs of aging, corrosion, or damage. Identifying and addressing problems promptly can effectively prevent fires.

Lightning Protection: For outdoor solar systems, consider lightning protection. Lightning strikes can cause sudden voltage surges that may damage the controller or even start a fire. Installing suitable surge protectors can provide additional safety.

Conclusion

Solar charge controllers are essential components of any solar power system, but they can pose serious risks if not properly managed. Understanding the critical reasons for a solar charge controller catching fire—such as overheating, loose connections, poor-quality components, and improper installation—is the first step toward prevention. By implementing safety measures like proper installation, regular maintenance, and using high-quality equipment, you can significantly reduce the risk of fire and ensure the safe operation of your solar power system.

Remember, safety should always be a top priority when dealing with electrical systems. If you’re unsure about any aspect of your solar charge controller’s installation or maintenance, don’t hesitate to consult a professional like HearGrow with Consultation. With the right knowledge and precautions, you can enjoy the benefits of solar energy system while keeping your system safe and reliable for years to come.

Reference:

1:How to use solar charge controller 2020 -See How To Set Up PWM 30A 20A 10A Solar Charge Controller Available in Youtube https://www.youtube.com/watch?v=_gSo-7Uu4Z0

2:Illustration of Fired Possibility in Devices of Solar Controller Due to loose Connectorhttps://heargrow.com/illustration-of-fired-possibility-in-devices-of-solar-controller-due-to-loose-connector/

3:PVsyst：https://www.pvsyst.com/

4:SolarDesignTool https://solardesigntool.com/

6:Solar Panel Simulator https://www.solarschools.net/