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Faults in Power Station and their Solutions

Due to the fact that portable power stations have both batteries and AC power output, users often encounter various problems when using portable generators, especially when a solar power station is used for more than 3 years, there will be more detailed issues. Some of these faults are due to issues with the PCB circuit board, some are caused by battery aging, and some are other problems.
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Types of faults in power stations

With the increasing recognition and purchase of portable power stations and solar generators by the general public, the popularity of portable power stations worldwide is growing, resulting in a growing number of power station failures. From the issues summarized by our factory's after-sales service team, it can be seen that portable power stations and solar generators are prone to these types of malfunctions:1. Battery failure in the power 
station; 2. The charger of the power station has malfunctioned; 3. The power output of the power station has malfunctioned (divided into AC output and DC output); 4. Control panel malfunction, 5. Button malfunction; 6. Other malfunctions caused during transportation.

Battery faults of the power station

The battery problems of portable solar power generators generally manifest as the following phenomena, which may be caused by different reasons for different phenomena.
1) After the power station is connected to a charger or solar panel for charging, the display screen of the power station shows that the battery is being charged or fully charged, but after disconnecting the charger, the power station displays no increase in battery capacity. Most of the reasons for this phenomenon are due to problems with the resistors or other components controlling the power station, such as short circuits in capacitors or resistors. If the specific component that is at fault can be identified one by one, the corresponding component can be replaced. Generally, ordinary power station users do not have professional operating tools or circuit knowledge in this area. Therefore, it is best to replace the control panel for the power station.
150 watt power station
2) After charging the portable power station continuously for a few minutes, the power display shows that the battery is fully charged, but the actual battery is not fully charged. This phenomenon can easily occur in portable power stations made of lithium battery packs, because the batteries in the power station are not composed of individual batteries, they are often composed of more than 10 or dozens of batteries combined. Due to the fact that the voltage or capacity of the batteries cannot be 100% the same last night during the production process, as the portable power station continues to use, the technical parameters between each battery will become increasingly different. Over time, one of the batteries will have insufficient capacity. For example, the standard capacity of the battery was originally 20000Mah, but over time, the capacity of the worst battery will gradually decrease to 500Mah or even less. Because of this battery, all batteries will be charged to 500Mah and automatically display as fully charged. However, the actual capacity is still far from reaching 20000 mAh, This is the phenomenon where a portable power station shows sufficient power after charging for a few minutes, but the actual battery is not fully charged. Therefore, if this phenomenon occurs, it is obviously a problem with the battery, and only the battery pack of the portable power station needs to be replaced.
3) After the power station is fully charged, the rate of electricity consumption is very fast when using electrical appliances. If such a phenomenon occurs, it needs to be divided into two situations. If
it is a portable power station made of lithium batteries, it is generally because the battery pack is damaged and needs to be replaced; If the portable power station is made of lead-acid batteries, it is likely that the batteries have aged due to prolonged use. The lifespan of lead-acid batteries is relatively short (usually 500 cycles), and after about six months of use, the battery capacity of lead-acid batteries will decrease to about 50%. If the batteries are not charged in a timely manner after each use, they are more likely to be damaged and have a shorter lifespan. So, if such a phenomenon occurs, new lead-acid batteries can be replaced, or users need to charge the power station in a timely manner after each use, and do a good job in maintaining the power station.
4) After about half an hour of use, the battery position of the portable power station becomes very hot. During the operation of the battery (continuous charging or continuous discharging), it is indeed prone to generate a large amount of heat, especially during summer use. This heating phenomenon is more obvious. As long as the machine temperature does not exceed 60 ℃ during the operation of the portable generator, it is a normal phenomenon. Just pay attention to the ventilation and heat dissipation of the power station, and there is no need to pay too much attention; If the portable power station continues to generate heat exceeding 60 ℃ during operation, the user can cut off the power or shut it down, allowing the power station to pause for a period of time and wait for the temperature to drop before continuing to use it.
300 watt power station

Charger faults of the power station

Users often encounter such phenomena when charging portable power stations, such as the continuous flashing of the charging indicator light or the failure of the charging indicator light to light up, both of which are abnormal phenomena. According to the charging standards of portable power stations, the rated voltage of the charger is generally between 14.4-15V. If the above two situations occur during charging, it is likely due to insufficient voltage of the charger, or a short circuit in the circuit connecting the control panel of the power station to the charger. Another possibility is that the accuracy of the technical parameters of the program is not sufficient. So, if the indicator light of the charger does not light up or flashes continuously, the first thing to confirm is whether the charger itself is good. If it is a problem with the charger, it needs to be replaced with a new charger. If the charger is good, it is likely to be a problem with the control panel, which requires a new control panel for the portable power station.
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The power output failures of the power station

The power output methods of portable solar power plants generally include DC direct current output, USB direct current output, Type-C direct current output, and AC alternating current output. There are many reasons that can cause power output failures, and the most common reason is that the solder joints between the output terminals and connecting wires are not firm enough, and the solder joints are loose, resulting in poor contact; Another possible reason could be that the MOS transistor on the PCB circuit board is damaged; The third reason may also be the result of the solder joints of components such as capacitors and resistors falling off or failing to be successfully soldered; The fourth reason may be that the socket is loose, causing poor contact; The last possible reason may be that the slot position of the portable power station's exhaust fan is not tightly pressed. If the abnormal power output is caused by the first three reasons, the PCB motherboard needs to be replaced. If the abnormal power output is caused by the fourth and last reasons, we only need to fix the socket or exhaust fan slot position firmly to solve the problem.
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150w portablet power station charger
3000 Watt Home Solar Generator

About PCB faults of the power station

PCB circuit board is the core component and brain of portable power stations. The production process of PCB circuit board is a very refined work, which requires the cooperation of professional machine equipment (SMT surface mount equipment) and trained and qualified operators to complete this work. Because every capacitor, resistor, or other electronic component on the PCB board plays an irreplaceable role, they control a subtle product function according to the requirements of the developer's development program. So, when users discover that the PCB circuit board of the power station has malfunctioned, it is best to replace it with a brand new PCB circuit board for the portable power station.
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The button faults of the power generator

When users use the power station, there are usually two types of malfunctions with the buttons: one is that the button does not light up when turning on, causing the power station to not start up properly; Another phenomenon is that the button can turn on the power normally, but when connected to the DC output plug or AC output plug, the button will turn off within a few seconds, and the power station will also automatically shut down. If it is the first type of button not lighting up, it is highly likely that the touch spring of the button has deformed, causing it to lose its elasticity, or the glue has stuck to the touch spring when covering the power station, resulting in the touch spring not being able to function properly. If it is the phenomenon of the second button turning off, the most likely reason is that the total power of the appliances used exceeds the peak power of the portable power station, because the output current of the power station is overloaded, causing the power station to enter self-protection mode. This is not fundamentally a problem with the button, it is a normal phenomenon.
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200 watt solar generator
Mini Solar Generator

Other failures during transportation

Due to the relocation of the power station during transportation, it is easy for components to be damaged due to vibration, resulting in power station failures. For example, damage to the power station's casing and loosening of spare parts caused by collisions are inevitable occurrences.
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