Common Failures &

Troubleshooting
T1/T2 Training

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Learning Objectives

1 Identify types of common failures in PV systems

and their causes

2 Give recommendations of preventive and corrective

measures for common failures

3 Describe basic troubleshooting principles for PV

system and its components

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Common Failures – Grid-Connected PV Systems

* Inverter
Slide Source: IEA PVPS, 2007
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Common Failures – Stand-Alone PV Systems
 Battery Failure:
 UPS systems: Batteries did not last more than 2 years –
Batteries not maintained (Mozambique, Tetra Tech, 2010)
 Small automotive batteries are connected to the solar system
(Guyana, Tetra Tech, 2012)

 Inverter Failure: 90 water pumping systems investigated -

22 hardware failures (70% due to inverters) - Poor inverter
design (IEA PVPS, 2003)
 Charge Controller Failure: Solar home systems (SHS) –
Most problems were related to charge controller set points
(Zimbabwe, IEA PVPS, 2003)

Slide
4 Source: Poweringhealth.org
Common Failures – Stand-Alone Systems Cont’d

 Quality Standard: Bad quality SHS components were

reduced by World Bank Quality Standard in Western
China (IEA PVPS, 2003)
 Capacity Sustainability: All the staff present during
installation training had been transferred to other health
centers at the time of the real system installations
(Mozambique, IEA PVPS, 2003)

Slide
5 Source: Poweringhealth.org
Common Failures – Stand-Alone Systems Cont’d

 Disconnect between system usage

and system design
 Lack of understanding about
limitations of PV system
 Serious lack of maintenance
 Lack of attention to maintenance
priorities
 No maintenance policy
 Lack of local capacity to offer
maintenance services
 Long lead time for maintenance calls Slide
6Source: Tetra Tech, Guyana, 2012
Common Failures – Stand-Alone Systems Cont’d
 Recommendations
 Consult and educate end-users on good
operational behaviour
 Make maintenance a priority
 Develop, promote maintenance policies
 Train local technicians and encourage
entrepreneurial activity
 Train end-user to perform routine
maintenance Battery Terminal Corrosion

 Allocate budgets for maintenance, as well

as for training
 Further insist on ensuring maintenance in
every single installation Slide
7Source: Tetra Tech, Guyana, 2012
Common Failures – Stand-Alone Systems Cont’d

Slide Source: JiCA

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Common Failures – PV Modules

“I have been to a remote island where almost all panels

for the 20-30 systems installed were in shade … leading
to accelerated battery failure. There was no village
technician to look after the systems and hence everyone
was back to kerosene lamp - until another donor
rehabilitated the systems. Simply pruning the trees would
have saved the systems in the first place.”
Dr. Atul Raturi, USP, Fiji

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Common Failures – PV Modules
 PV module
 Low or no power output
 Causes
 Wrong orientation (wrong tilt angle)
 Accumulation of dust
 Crack in the glass lamination
 Shadow
 Climate condition
 Short circuit of bypass diode
 Loose connection of wires
 Theft Slide Source: JiCA
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Troubleshooting – Checking PV Modules

 Check for the following:

 Rectify orientation and title angle (tilt angle must not
be < 10o facing north)
 Presence of dust and cracks
 Clean PV with water, detergents not needed
 Tighten loose connections at the terminal box
 Shadowing at PV module between 9am – 3pm
 Bypass diode

Slide Source: JiCA

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Troubleshooting – Checking PV Modules Cont’d

Slide Source: JiCA

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Common Failures Examples - Delamination

Source: University of South Pacific Source: USAID/VOCTEC

 Severe delamination  Severe delamination

 Site: Nabouwalu, Fiji  Site: Atata, Tonga
 PV-Wind-Diesel Hybrid System  Stand-alone residential system
 Commissioned in 1998  Age: Unknown
 PV system became non-operational after  System still operational
2 years due to failures of electronics  Photographed in 2012
 Photographed in 2009
 Currently only diesel system supports the loads
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Common Failures – Systems Delamination

 Delamination could lead to electrical shock, and it leads to

dramatic power loss

Electrical
Shock
+ Voltage
= &
Power
Decrease

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Common Failures – System Browning

 Browning may not lead to electrical shock, but it will lead

to dramatic power loss

Current (A)

Voltage (V)
Slide Source: ASU
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Common Failures – Battery

“Customers end up buying automotive batteries for their

solar system … Wet-lead acid batteries are not
maintained properly, customers and even some small
companies end up filling the water collected from the iron
roof or simply the tap water. I came across a situation
where customer end up filling coconut water in the
battery. Toping up batteries with sulfuric acid instead of
distilled water has been a problem as well”
Amit Singh, CBS Power Solutions, Fiji

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Common Failures – Battery
 Battery
 Easily discharged
 Cannot be charged
 Unequal cell voltages
 Causes
 Sulfation
 Dried up battery solution
 Stratification
 Loose connection at the terminals
 High battery temperature (keep low ambient temperature)
 Leakage of electricity due to acid surface between battery
terminals Slide
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Source: JiCA
Troubleshooting – Battery

 Check for the following:

 Loose connection at the terminals
 Clean terminals with steel brush and apply grease (e.g.,
Vaseline or lithium grease)
 Level of battery electrolyte, top up when necessary
 Use appropriate terminal lugs/clamps only
 Presence of corrosion at the terminals
 Slightly shake battery (not > 10o from the floor line at side)
to avoid stratification
 The installation condition, relocate if necessary
 The battery performance Slide Source: JiCA
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Troubleshooting – Battery Performance
 Checking Amp-Hour Capacity
 After fully charging battery, use a
constant load to draw electricity
 Disconnect the load at LVD
 Compare the rated amp-hour
capacity with measured amp-hour
capacity
 If measured amp-hour is less than
80% of the rated capacity, the
battery has almost reached the end
of its usefulness
Slide Source: JiCA
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Troubleshooting – Battery Voltage

 Checking the battery voltage

 After fully charging battery, stop the
charging
 After minimum 10 minutes, but
typically 2 hours, measure the
battery voltage
 If the voltage is lower than 12.5V,
the battery has almost reached the
end of its usefulness

Slide Source: JiCA

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Troubleshooting – Battery

 Battery can not charge fully in spite of a sunny day

Note: a typical way to troubleshoot is to disconnect and test individual components.

Slide Source: JiCA
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Common Failures – Battery Sulfation
 Battery sulfation is the major
failure mode
 Conclusions:
 VRLA (valve regulated lead-acid)
and flooded lead-acid batteries
are better than the low
maintenance flat plate LA
batteries
 Pulse Width Modulation (PWM)
charge controllers are better than
the conventional on-off type
charge controller
Slide
Source: June 2012, MNRE-CECRI, India
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Common Failures – Charge Controller

“Charge controllers and inverters used are with very low

LVD settings, I have seen inverters with 9.5V LVD
setting. This affects the battery.”

“Even with small solar systems customers end up

connecting large 1kW, 2kW or even 3kW inverters
thinking that the inverter generates power.”
Amit Singh, CBS Power Solutions, Fiji

Note: typically small solar PV systems are less than 300 Watts.
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Common Failures – Charge Controller

 Charge controller
 No current is flowing to the battery
 Signals fully charged though
battery is just being charged
 Keeps charging even when fully
charged
 Causes
 Blown fuse
 Loose connection of wires
 Malfunction of internal circuit Slide Source: JiCA
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Troubleshooting – Charge Controller

 Check for the following:

 Voltage at the terminal and output
current
 Loose connections at the
terminals
 Blown (open) fuse
 HVD and LVD settings, rectify
settings as necessary

Slide
Source: JiCA
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Troubleshooting – Charge Controller Cont’d

 Charge controller can not operate properly

Slide Source: JiCA

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Troubleshooting – Checking Charge Controller

Slide Source: JiCA

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Common Failures – Balance-of-Systems (BOS)

“A major contributor to faults in systems is poor cable

connections whether arising from initial installations or
through lack of routine maintenance to check cable
connection integrity. Add in a tropical maritime
environment and if the cable connection is exposed to
the outdoor environment [,] it accelerates the onset of a
connection fault.” Bruce Clay, ClayEnergy, Fiji

“Cables don’t have mechanical and electrical protections.

Non-insulated cables are used. No disconnection and
fault current protection devices are installed.”
Slide
Amit Singh, CBS Power Solutions, Fiji
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Common Failures – Balance-of-Systems (BOS)
 BOS (cables, switches, lights, etc.)
 No light even when battery is
fully charged
 Under-voltage at load end
 No power at load end
 Causes
 Open or short circuit or grounding
 Inappropriate/undersize cables (large voltage drop)
 Burn-out DC light tube/inverter
 Loose connection at the terminals
 High resistance on the switch contact Slide Source: JiCA
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Troubleshooting – BOS
 Check for the following:
 Voltage level at load end and voltage drop
 Possible loose connections at the terminals
 Size of cable if the installed cable is the appropriate size,
replace as necessary
 Continuity of cables, when open circuit, trace the line and
connect the open circuit
 Possible short circuit and grounding in the line, re-insulate
short-circuited/grounded line
 Operation of switch and voltage drop between input and output

Slide Source: JiCA

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Troubleshooting – Overall System

“Equipment component level corrosion leading to fault.

This can be due to the equipment design not being
[un]suitable for the environment or through incorrect
installation where equipment enclosures are not sealed
as per instructions leading to ingress of water or tropical
maritime air.
Also insect infestation can lead to faults whether by ants,
wasps or small lizards (geckos). We often see
enclosures or for instance array combiner boxes etc
either not closed properly or missing cable glands etc”
Bruce Clay, ClayEnergy, Fiji
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Troubleshooting – Overall System

 The usage hour of appliances is getting shorter than usual

* Charge controller or inverter

Slide Source: JiCA
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Troubleshooting – Overall System Cont’d
 Appliances can not use even with correct connection of battery

 The interval of water refilling is getting shorter than usual

Slide Source: JiCA

* Charge controller or inverter 33
Troubleshooting – Checking System’s Voltage Drop

Slide Source: JiCA

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Troubleshooting – Spare Parts
Diesel Generator PV System Batteries
• Fuel filter • Spare fuses • Distilled water
• Air filter • Wire nuts • Baking soda to
• Lubrication oil • Wire neutralize spilled
• Engine coolant • Mid detergent for battery acid
• Oil cleaning solar vinegar if working
• Transfer switches modules with water with alkaline
• Voltage regulator • Spare switches batteries *
• Starter • Connector strips • Petroleum jelly to
• Belts • Energy efficient protect battery
• Battery cables light bulbs terminals
• Sandpaper to clean
corroded battery
terminals
• Spare battery
cables
Recommended spare parts and supplies for diesel and PV systems

* Alkaline batteries are not typically used in stand-alone PV systems Slide

Source: USAID
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Practice

 Discuss some of the common failures that occur in PV

system and list their potential causes.
 Low power output from module: wrong tilt/orientation, dust
build up, shading by nearby object, crack in glass/lamination,
etc.
 Battery easily discharged/unable to charge: sulfation, dried
up solution, stratification, loose connections, etc.
 No current to battery/battery won’t stop charging: no current
from PV module, loose connection from charge controller to
battery, internal circuit malfunction in charge controller, etc.

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Practice Cont’d

 Discuss some remedies to the common failures in PV

systems.
 Make maintenance a priority, especially battery
 Train local technicians in maintenance procedures and
encourage entrepreneurial activity
 Allocate funds for both maintenance and training
 Maintain spare parts

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Practice Cont’d

 Describe some basic troubleshooting principles for PV

systems and their components.
 Modules: check tilt/orientation, cut nearby vegetation, check
for cracks, clean surface, check connections, etc.
 Battery: slightly shake to avoid stratification (flooded), check
for presence of corrosion products at terminals, check
connections, check level of battery solution if flooded and
vented, check battery health using a discharging technique,
etc.
 Charge controller: check voltage and output current, check
wire connections, check HVD and LVD settings
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Summary – Key points
 Common failures of PV systems include: battery failure, inverter
failure, charge controller failure, PV module failure, etc.
 Most of the common failures are due to lack of maintenance
 Recommendations to address system failure include:
development of policies, training local technicians, maintaining
spare parts, encouraging entrepreneurial activity, etc.
 Troubleshooting principles can be applied for PV system and its
components, such as shade control, cleaning PV modules, adding
distilled water, cleaning battery terminals etc.

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