One of the most frequent issues is the improper installation of solar modules. This can cause mechanical stress, which in the worst case leads to cracks in solar cells or the glass. Such damage reduces system performance and increases vulnerability to further problems such as water ingress.
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Grounding often neglected
Proper grounding is essential to prevent power surges and electromagnetic interference. Inadequate grounding can also result in electrical accidents and damage to sensitive electronics.
Most components are exposed to weather around the clock. Incorrect installation that fails to protect against moisture, dirt or UV radiation can cause corrosion, insulation damage and other faults that impair system efficiency and safety.
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UV radiation, temperature changes and humidity can cause ageing and brittling in cable management components. This can lead to failures and permanent efficiency losses, as damaged parts degrade system performance.
Damaged cable insulation
Poorly routed cables and exposure to moisture or corrosion can damage cable insulation. Often this results in inverter failure, since inverters rely on a stable, uninterrupted voltage supply. Such failures are costly and time-consuming to fix.
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Unprofessional cable routing and long-term UV exposure on rooftops can make cables brittle. Routing through raised roof tiles is not a durable solution, as it often leads to leaks and, in extreme cases, chafed insulation and short circuits.
The special challenges of open-air spaces
Installers and operators face additional challenges with open-air ground-mounted systems, which are key to the energy transition. One critical point: cables hanging under modules can entangle sheep or other animals, potentially harming both the system and the livestock.
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Careful cable management is also important to reduce the load on module junction boxes from cable weight. These loads can increase further with snow or ice. Professional guidance on cable ties and mounting elements helps protect equipment and wildlife, and reduces the risk of damage during mowing. (HS/TF)
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The author: Thaddäus Nagy is Executive Director of EMC-direct. Over the past two years, he and his team have helped construct numerous large-scale open-air systems across Europe. Products from the cable protection and fastening specialist, based in Dorsten near Gelsenkirchen, have been used in major solar projects in Austria and Denmark.
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