4：Why Does a Solar Controller Experience Charging Stagnation (Freeze or Dead State) During High-Current Charging?

A solar controller may experience charging stagnation, also known as a freeze or dead state, during high-current charging due to several potential causes:

1:Overheating Protection:

High current charging can cause the internal temperature of the solar controller to rise rapidly. If cooling is inadequate or environmental temperatures are too high, the controller may activate its overheat protection mechanism, stopping operation or entering a stalled state to prevent damage.

2:Hardware Limitations:

The hardware design of the controller might not be capable of handling such high currents. For instance, MOSFETs, diodes, or other power components used may have lower rated current capacities. When actual current exceeds these ratings, the components may fail or enter a protective mode, causing the controller to malfunction.

3:Software/Firmware Issues:

There could be bugs or misconfigurations in the internal microprocessor or firmware of the controller. Under specific conditions, such as high current input, these issues can lead to system crashes or unexpected states, resulting in what is perceived as a “freeze.”

4:Power Supply Instability:

Unstable supply voltage or transient spikes can interfere with the controller’s normal operation, especially under high current conditions, leading to abnormal behavior and potential stalling.

5:Connection Problems:

Incorrect wiring or poor connections can cause abnormal behavior at high currents. For example, high resistance in connection cables or loose terminal connections can generate excessive heat or voltage drops that affect the controller’s performance.

6:Load Characteristics:

Certain types of loads may demand very high instantaneous currents upon startup, which can exceed the solar controller’s design limits and cause temporary failure.

7:Component Failures:

Critical components inside the solar controller may fail, such as aged capacitors or cracked solder joints on the printed circuit board, issues that become more apparent under high current conditions.

8:Improper Settings(Can Refer the Setting Guide from Youtube):

If the solar controller settings are incorrect, such as an improperly set maximum charging current, the controller might take measures to prevent overload when actual charging current approaches or exceeds this value, manifesting as a stall.

Recently, customers have reported that some units of the CPT and CPW series solar controllers experience charging stagnation (freeze or dead state) during high-current charging. After returning these units to the factory and conducting on-site verification, it has been confirmed that there is a potential hazard present, which can be resolved by replacing certain components.

Analysis:

It has been determined that between 2022 and March 2023, some batches of two particular components may have inconsistent parameters, making them prone to causing the device to stop operating.

Solution:

Free Component Replacement: We offer free replacement of the affected components or provide the necessary components for customers to replace themselves. Please contact our sales department to arrange this service.

Not All After-sales Require Component Replacement: It is important to note that not all after-sales issues require component replacement. Other problems such as loose wiring harnesses or overvoltage damage should be confirmed with us before proceeding with any solution.

Summary

To avoid charging stagnation, invest in a high-quality MPPT solar controller with a sufficient current rating, advanced thermal management, and compatibility with your battery type. Proper installation, regular maintenance, and monitoring are also essential to ensure smooth operation.

Don’t be afraid,Heargrow can provide more solution for you.