Investing in Solar Power Plants (PLTS), whether rooftop, ground-mounted, floating, off-grid, or hybrid systems—offers energy efficiency and long-term reductions in operational or electricity costs.
However, achieving peak performance is often hindered by technical errors during the design and installation phases. These errors can have adverse consequences for the system owner or user.
Neglecting electrical, mechanical, and environmental standards not only leads to reduced power output (underperformance) but also risks triggering hazards such as arc faults, battery damage, and even structural failure. Below are various common errors in solar power system installation.
1. Incorrect Orientation, Tilt Angle, and Shading Analysis
Installing solar panels without considering site geometry and surrounding obstructions is a fundamental error.
a. Impact
Sunlight obstruction, even if it covers just a single solar cell, can drastically reduce the current within a string.
Recurring shading triggers the formation of "hotspots" (areas of excessive localized heat) that permanently damage the cell layers. Additionally, an incorrect tilt angle prevents the panels from self-cleaning during rainfall.
b. Solution
In Indonesia (located near the equator), install panels with a minimum tilt of 10° to 15°, facing either North or South (depending on the specific latitude) to allow rainwater to wash away dust.
Use simulation software (such as PVsyst or Helioscope) to map shading patterns throughout the year.
2. Errors in DC Wiring and MC4 Connector Installation
Solar power systems generate high-voltage direct current (DC), which requires different handling compared to standard AC electrical systems.
a. Impact
Using standard pliers (non-crimping tools) to install MC4 connectors, or mixing connectors from different manufacturers, can create high-resistance gaps.
This is a primary cause of DC arc faults, which are the leading trigger for fires in solar PV systems.
b. Solution
It is mandatory to use solar PV-specific cables (EN 50618/TÜV) that are resistant to UV radiation and extreme weather.
Use calibrated MC4-specific crimping tools and ensure that cable connections are not left dangling or submerged in water.
3. Mismatched Sizing of Inverter and Solar Charge Controller (SCC)
Imprecise sizing of energy conversion components compromises the system's overall efficiency.
a. Impact
On-Grid Inverter: A non-ideal ratio between panel (DC) and inverter (AC) capacities leads to clipping losses if the inverter is undersized, or reduced efficiency during low-irradiance periods if it is oversized.
SCC (Off-Grid/Hybrid Systems): Choosing a PWM-type SCC instead of MPPT for medium-to-large systems results in a loss of 20–30% of potential energy, as the controller fails to track the solar panels' maximum power point.
b. Solution
Maintain a DC/AC ratio within the 1.1 to 1.3 range and use MPPT-type Solar Charge Controllers for all battery-based systems to ensure optimal energy extraction from the PV array.
4. Incorrect Battery Configuration and Management (Off-Grid & Hybrid Systems)
In isolated (off-grid) solar installations or energy storage systems (ESS), batteries represent the largest cost component and are highly susceptible to damage if installed incorrectly.
a. Impact
Unbalanced wiring between battery banks causes some battery cells to experience overcharging or over-discharging. Ignoring Depth of Discharge (DoD) and ventilation requirements for lead-acid or lithium batteries can reduce their service life by up to 50%.
b. Solution
Install a compatible Battery Management System (BMS).
Use a diagonal cabling configuration (busbar balancing) to ensure current is distributed evenly across all battery units, and house the battery bank in an air-conditioned or well-ventilated room (ideal temperature: 20°C–25°C).
5. Anchoring Failure and Structural Material Selection (Mechanical)
Issues with mounting structures frequently occur in both ground-mounted and floating systems.
a. Impact
Using frame materials that lack standard anti-corrosion coatings (such as Hot-Dip Galvanized steel or C4/C5-grade anodized aluminum) causes the structure to rust within a few years.
For ground-mounted solar PV systems, failure to conduct soil bearing capacity tests (geotechnical testing) can lead to anchoring failure during high winds.
b. Solution
Calculate wind and seismic loads in accordance with local building standards. Use anchoring systems (ground screws or concrete foundations) tailored to the project site's soil type and topography.
6. Skipping Commissioning and Pre-Operation Testing Procedures
Engaging the main circuit breaker without performing viability testing technical [aspects] involve high-risk practices.
a. Impact
Polarity errors, cable insulation leakage to ground (earth faults), or unbalanced string voltages can instantly damage the inverter's internal components the moment current flows through the system.
b. Solution
Conduct thorough commissioning tests:
- Test open-circuit voltage and short-circuit current.
- Perform insulation resistance testing (megger test) on DC cable strings.
- Conduct thermal imaging inspections to detect potential hotspots or loose connections before the system is handed over.
Solar PV System Errors Can Affect You
The success of a solar PV installation depends not only on the quality of the solar panel or inverter brands used but also on meticulous planning, the selection of supporting materials, and adherence to electrical and mechanical safety standards.
Engaging certified experts and implementing rigorous testing procedures ensures your solar PV system operates optimally, safely, and reliably for decades.
Batari Energy is a trusted solar PV installation service provider employing certified expert technicians. Our CTO, Aji Insan Kamil (S.Si, M.Si), is a certified technician and an expert in electronics and solar PV systems.
Batari Energy’s solar PV systems utilize in-house manufactured batteries, allowing for reduced battery costs. We provide installation services for on-grid, off-grid, and hybrid solar PV systems, available anywhere across Indonesia.
Interested in Batari Energy's solar PV installation services? Click this link for more information!