In practice, installation errors are one of the most common reasons for damage and power losses in photovoltaic systems. They are often caused by ignorance, time pressure or the use of unsuitable materials. It is therefore crucial for installers and planners to recognize typical weak points at an early stage and to consistently eliminate them - because many problems do not show up immediately, but develop gradually over months or years.
The article bundles the most important risk areas and classifies them in such a way that they can be used directly in everyday project work.
The topic was also addressed in a specialist article by EMC-direct on photovoltaik.eu .
Why installation errors can be so expensive in the long term
Unlike obvious defects, the pitfall of many installation errors is that they initially remain inconspicuous. Mechanical stresses in modules, inadequate protection against the weather or weaknesses in the electrical installation can permanently reduce efficiency. If UV radiation, temperature changes and humidity are added to this, the ageing of individual components accelerates - with consequences that can even lead to the failure of entire strings.
Mechanics and roof design: when the basis is not right
Incorrect module installation is a particularly common problem. If solar modules are not installed in accordance with the specifications, mechanical stresses can occur that put strain on the structure of the module. The consequences range from subtle cell damage to visible damage - and therefore measurable yield losses.
"This can lead to mechanical stresses in the modules, which in the worst case can cause cracks in the solar cells or the glass."
Source: EMC-direct, published on photovoltaik.eu
It becomes critical when such damage is coupled with moisture ingress: this increases the susceptibility to further degradation. There are additional risks on the roof. Temporary roof penetrations or cable routing that is permanently exposed to UV radiation can cause cables to become brittle. If the insulation is chafed as a result, the path to short circuits and consequential damage to components is not far away.
Practical focus: cable routing on the roof
Every detail counts in the design. A roof feed-through "via the raised roof tile" appears to be a quick solution in the short term, but often leads to leaks and mechanical stress on the cables in the long term. As a result, repair costs and the risk of unplanned downtime increase - both factors that operators pay for particularly dearly.
Electrical installation and earthing: safety starts with the details
In addition to the mechanical installation, the quality of the electrical installation is decisive for safety and reliability. Proper earthing is a key element in protecting the system from overvoltages and preventing faults.
"Proper earthing is therefore essential to avoid overvoltages and electromagnetic interference."
Source: EMC-direct, published on photovoltaik.eu
Earthing errors can not only damage electronic components, but also increase the risk of electrical accidents. For specialist companies in Germany, this means that the protection concept, choice of materials and design must fit together - and be consistently checked during acceptance.
Cable management under the influence of the weather: the underestimated permanent stress
Photovoltaic systems are constantly exposed to demanding weather conditions. If adequate protection against moisture, dirt and UV radiation is not taken into account during installation and material selection, there is a risk of corrosion, insulation faults and premature material fatigue.
"UV radiation, temperature fluctuations and moisture can cause cable management components to age and become brittle."
Source: EMC-direct, published on photovoltaik.eu
Poorly routed cables also increase the risk of insulation damage - for example due to moisture, corrosion or chafing. In practice, this often results in inverter failures because the devices are dependent on a constant and uninterrupted voltage supply. Such failures are costly and tie up time, which is usually in short supply on construction sites.
Ground-mounted systems: additional risks from animals, snow and operation
In ground-mounted systems, special stresses are added. Loose cables or cables hanging under modules can become a hazard if animals get caught in them. At the same time, additional weight from snow or ice increases the mechanical load. Consistent cable management reduces these risks, relieves the strain on junction boxes and plug connections and minimizes damage - even during maintenance work such as mowing.
Conclusion: less improvisation, more standard
Installation errors are rarely "a single slip-up". It is often a chain of small imperfections that lead to performance losses, failures and increased maintenance costs under real environmental conditions. If planning, materials and execution are properly dovetailed, risks are noticeably reduced - and yield and safety are protected over the entire service life of the system.
The free white paper on the safe operation of photovoltaic systems provides in-depth information on common causes of damage and preventive measures.
Author: Thaddäus Nagy, Managing Director EMC-direct
Source & further information: www.photovoltaik.eu