DIY Solar Health Check: A Step-by-Step Guide to Annual PV System Maintenance
A solar PV system doesn’t demand much attention, but a yearly health check can keep it running smoothly and extend its life. You don’t need to be an engineer for this. With a few simple inspections and basic precautions, you can catch small issues before they turn into expensive repairs.
This guide walks you through a full, DIY annual maintenance routine covering panels, wiring, mounting hardware, inverter health, and common fault codes.
1. Start With a Visual Panel Inspection
Most system issues begin with the modules. A slow, careful visual check can reveal 70% of common problems.
What to look for:
- Cracks or hotspots: Hairline cracks, snail trails, or brownish burn marks indicate cell stress or microcracks.
- Glass haziness: Delamination or moisture inside the module shows EVA breakdown.
- Soiling build-up: Bird droppings, leaves, cement dust, ash, or pollution reduce irradiance and lower energy yield.
- Frame integrity: Check for loose edges, corrosion, salty deposits (common near coasts), and gaps in frame sealant.
Tip: Clean the panels only if necessary. Use mild detergent and soft water. Avoid aggressive scrubbing.
2. Check the Tilt, Orientation, and Mounting System
Panel angle matters for maximum energy harvest. Over time, fasteners loosen due to wind loads and thermal expansion.
What to inspect:
- Mounting bolts: Verify they are tight and rust-free. Stainless steel fasteners should not show pitting corrosion.
- Rail alignment: Rails should be straight, not sagging. Misalignment can stress the modules.
- Roof penetration points: Look for water seepage, broken flashing, or cracked tiles around mounting brackets.
- Tilt angle: If you installed adjustable mounts, ensure the seasonal tilt is still correct (Indian average: 20–28° depending on latitude).
3. Inspect DC Wiring and Junction Boxes Carefully
DC wiring carries high voltage even when the main switch is off. Do not open live connectors. Perform only visual checks.
Inspect:
- MC4 connectors: Must be fully locked, dry, and crack-free. Overheating shows as discoloration or melting.
- DC combiner box: Check fuses, SPD indicator windows (usually green = healthy, red = replacement needed), and the tightness of terminal screws.
- Cabling: Look for rodent bites, UV damage, brittleness, or cracked insulation.
- String configuration: Make sure no string has accidentally been disconnected (birds or monkeys often pull cables loose in some regions).
Important: Any smell of burnt plastic or signs of overheating need immediate professional attention.
4. Inverter Health Check: The Heart of Your Solar PV System
Your inverter logs most system events. Spend a few minutes reviewing its performance.
Steps to follow:
- Check the display or app:
- Review today's and monthly energy yield.
- Compare with last year’s data. A drop of more than 10–15% may indicate module degradation or connection issues.
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Look for warning LEDs:
- Green = normal
- Yellow = attention needed
- Red = fault / shutdown
- Ventilation:
- Ensure the inverter is dust-free, not blocked by clutter, and has at least 300 mm clearance for airflow.
- Check AC cable and MCB:
- Tighten the AC output terminals if accessible. Inspect MCBs and SPDs for discoloration or tripping marks.
5. Understanding Common Inverter Fault Codes (Simplified)
Here are the most frequent domestic inverter error codes and what they mean:
| Fault Code | Meaning | DIY Action |
|---|---|---|
| PV Isolation Low | Leakage current detected | Check for damaged DC wires, moisture on panels, water inside connectors. |
| Grid Over/Under Voltage | Your utility voltage is outside limits | Log the timing; inform DISCOM if frequent. |
| DC Overvoltage | Too many panels in series | Check string design; do NOT operate inverter until verified by technician. |
| No Grid / Grid Fail | Utility power missing | Check main breaker, RCD, and inverter AC MCB. |
| IPPV / Low Irradiance | Low sunlight or heavy cloud | Normal. Happens in monsoon or evenings. |
| Over Temperature | Inverter overheating | Improve airflow; clean vents; avoid direct sunlight on inverter. |
6. Verify System Protection Devices
A reliable solar system is not just panels and inverter—it's also the Balance of System (BoS).
Check the following:
- AC MCB rating: Should match inverter output current.
- DC fuses: Must match string current (usually 10A or 15A).
- Surge protection devices (SPDs): Indicator should be green.
- Earthing resistance: Ideally below 2 ohm for solar systems (needs a professional to measure, but you can visually inspect connections).
7. Check the Net Meter and Billing Pattern
If you are grid-tied, a quick meter check can reveal hidden issues.
- Look for Error Codes on the meter.
- Review the DISCOM bill to ensure "Solar Export" units are being accounted correctly.
- Compare import vs. export over last 12 months.
If the meter isn't recording export, the issue may be with CT/PT calibration or DISCOM configuration.
8. Monitoring System & App Review
If your inverter has Wi-Fi/GPRS monitoring:
- Check if logs were continuous.
- Verify inverter time settings (incorrect clock = wrong data).
- Watch for repeated dips in generation during peak sun hours—usually shading or string mismatch.
9. Safety First: What You Should NOT Do
- Do not unplug MC4 connectors while the system is ON.
- Do not attempt earthing resistance measurement yourself.
- Do not open the inverter casing.
- Do not climb onto a wet roof.
- Do not expose yourself to live AC or DC circuits.
If something looks serious, call a certified solar technician.
10. Keep a Simple Annual Checklist
A small record once a year helps track system health:
- Date of inspection
- Any professional service done
- Visible panel condition
- Wiring condition
- Mount condition
- Inverter logs & energy readings
- Fault codes (if any)
- Cleaning date
Over 5–10 years, these notes become extremely valuable during warranty claims.
Conclusion
A solar PV system is one of the most reliable technologies you can install at home. With an hour of DIY maintenance each year, you can keep your system producing safely and efficiently for decades. This simple routine helps prevent breakdowns, improve power generation, and protect your long-term investment.
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