The Most Common Things That Go Wrong With PV Systems & How To Fix Them
For solar professionals, delivering high-quality PV systems isn’t just about the panels or the brand of inverter you use. The real make-or-break moment often comes down to the construction process, where even small missteps can lead to long-term system issues, efficiency losses, or even safety risks.
Solis, one of the UK’s leading PV inverter manufacturers , recently shared some practical insights from the field on where PV system installations often go wrong, and how to fix them (or avoid the issue entirely) before they become a problem.. These insights can serve as a useful guide for installers looking to improve quality and avoid the most common pitfalls.
Here’s what to watch out for, and how to fix it before it becomes a problem.
- Poor Equipment Layout
From awkward inverter placement to cramped string configurations, poor layout planning can compromise both performance and safety. It’s one of the most common and costly mistakes we see.✅ Fix it:
Plan your equipment layout with thermal performance, access, and ventilation in mind. Keep inverters off the ground, leave at least 30 cm of clearance on all sides, and avoid enclosing them in tight or unventilated spaces.
- Improper Cable Management
Messy wiring isn’t just an eyesore, it creates real risks. Exposed cables, tangled runs, and poor routing can cause overheating, system errors, or even fire hazards.✅ Fix it:
Use consistent cable lengths, secure fixings, and clean routing paths. Keep wires elevated and protected, especially in rooftop systems where weather exposure is a factor.
- Weak Grounding and Surge Protection
Improper grounding or a lack of surge protection leaves the system vulnerable to lightning damage or equipment failure. It’s often overlooked, until it’s too late.✅ Fix it:
Follow local grounding specs strictly, and always install SPD (surge protection devices) for both DC and AC sides. Use torque tools to ensure connections are tight and compliant.
- Inconsistent Installation Practices
Without a set of on-site standards, teams can cut corners or apply inconsistent build techniques, leading to reliability issues later on.✅ Fix it:
Develop an internal install checklist and train teams on it. That includes torque specs, proper labeling, panel orientation, and cable dressing. Consistency leads to quality.
- Lack of Final Inspection and Testing
Rushing to commission a system without a proper inspection step can let small issues slip through the cracks, which could grow into major problems over time.✅ Fix it:
Always schedule a post-build QA check. Look for loose connections, debris, poorly fixed cables, or blocked airflow. Use tools like IV curve tracing or thermal imaging where possible.
Getting It Right From the Ground Up
The difference between a good system and a great one often comes down to the details — grounding, airflow, torque, and even the height of the inverter off the ground. These aren’t glamorous talking points, but they’re the things that shape long-term performance, safety, and customer satisfaction.
By bringing greater attention to the construction stage, solar installers can reduce callbacks, protect margins, and deliver better systems from day one.
Build Smarter with Solis
Want more practical tips to improve your PV installations? Solis has created a full guide packed with visuals and hands-on advice straight from the field. Solis is one of the most trusted names in the field, known for their reliable performance and proven success in both residential and commercial solar projects.
Solis products are now available in OpenSolar, ready to use in your next project proposal or system design. Create your free OpenSolar account today and start quoting with Solis in just a few clicks.
