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Thank you very much for your patience & helping me out. I missed attaching schematic today, tomorrow after reaching office I will share the same here.

True Sir, actually I have tested all possibilities in my lab, i intentionally increased temperature to 100+⁰ C by external heater which actually would never go in real life. Plus I also tested my system with Voltages upto 60V at Panel's connection. Still that component didn't failed like it does...

Dear Mr. Hedges, Thank you very much for your suggestion. I probably have missed this, will try to take the scope to the site and check the same.

Hello Mr. Antron, My Transistor is feeded by 44V (worst case) and Output= 15V, 6.8k is after emitter (which is at 15Volts), thus Power Dissipated in Transistor (Neglecting base current flow) = (Current Through Collector - Emitter) * (Vin - Vout) (CE Current= 15V/6.8k = 2.2 mA) power in...

My housing is of Aluminium Diecast (Glass in front) so i guess probably it behaves as shield for the charge controller. I might be wrong too. I will consider and check about same.

Thank you very much for your suggestion. But Shielding as in ?

Dear All, I have installed a PWM Solar Charge Controller for a off-grid street light system. Where specs are as follows: LiFePO4 25.6V Battery 60 Ah, Streetlight = 30W (rated to operate at Vin: 16-32 V DC), Charge Controller I have made is PWM charge Controller which is designed as per 24V...