DWS Solutions

📉 One Broken Panel Could Be Costing You More Than You Think

It's easy to look at a single cracked or damaged solar panel and think, "It's only one panel, we'll replace it later."
The reality is that a damaged module can have a much bigger impact than most people realise.
Depending on the nature of the damage, it can:
⚡ Reduce the output of the affected string
⚡ Trigger inverter faults or string alarms
⚡ Create hot spots within the module
⚡ Allow moisture ingress, leading to further deterioration
⚡ Become a potential electrical safety risk

📊 Behind the Numbers
The example below is for illustration purposes only. Actual losses will vary depending on system design, irradiance, site conditions, electricity tariffs, the type of module damage, and whether the fault affects only the module or the entire string.

Consider a 100kW commercial solar PV system using 550W modules.
If one damaged 550W module is no longer producing energy, it could result in approximately:
• 3 kWh of lost generation per day
• 90 kWh per month
• 1,080 kWh per year
At an electricity tariff of R3.00/kWh, that's approximately:
💰 R3,240 per year in lost energy value from just one module.

In some cases, the impact can be even greater if the damaged module affects the performance of the entire string or causes the string to trip offline.

The takeaway?
A single broken panel may seem insignificant, but delaying repairs can reduce system performance, lower your return on investment, and increase the risk of more costly failures over time.

Don't let one damaged module become a much bigger and more expensive problem.

Would you replace one broken panel today, or risk paying for its impact over the next year?

⚠️ The Importance of Compatible PV Connectors

One of the most commonly identified issues during solar PV inspections is the use of mismatched PV connectors.
Although connectors from different manufacturers may appear to fit together, they are not always designed, tested, or certified to operate as a compatible pair. This can increase electrical contact resistance, which may contribute to heat build-up over time.

The connector shown below was removed from a solar PV system after visible thermal damage was identified during an inspection.
While every case should be assessed individually to determine the exact cause, connector compatibility is one of the critical items that should always form part of a comprehensive Operations & Maintenance inspection.

Routine inspections can help identify:
✅ Connector compatibility
✅ Signs of overheating or deterioration
✅ Poor electrical connections
✅ Installation defects
✅ Components requiring corrective maintenance

Small components can have a significant impact on the performance, reliability, and safety of a solar PV system.

At DWS Solutions, our Operations & Maintenance programmes are designed to identify potential issues early, helping clients maximise system performance, improve reliability, and reduce the risk of unexpected failures.

📞 Is your solar PV system due for an Operations & Maintenance inspection? We'd be happy to help.

Image captured during a site inspection and shared for educational purposes.

🌧️ MYTH VS FACT

Myth: Rain cleans solar panels.

🚗 Think about your car...
If your car is covered in dust and dirt, would one rain shower leave it spotless?
Probably not.

The same applies to solar panels.
While rain can help wash away loose dust, it often isn't enough to remove:
🐦 Bird droppings
🌿 Pollen and organic matter
🏭 Pollution and airborne contaminants
🌊 Salt deposits in coastal areas
🌬️ Dirt that has baked onto the glass surface

In some cases, rain can even leave behind water spots and residue as it dries.
Why does it matter?
Solar panels rely on sunlight reaching the solar cells beneath the glass.
When dirt accumulates, less sunlight reaches the cells, which can reduce energy production.

The impact depends on:
☀️ The amount of soiling
☀️ The type of contamination
☀️ The location of the site
☀️ The system design

Some studies have shown that heavily soiled panels can experience significant performance losses compared to clean panels.

The takeaway
💡 Rain helps.
💡 Rain does not replace inspections.
💡 Rain does not guarantee clean panels.

Just because a solar array has been through a few rainstorms doesn't mean it's operating at its best.
Have you ever seen a solar array before and after a proper clean? The difference can be surprising.

👇 Do you think rain is enough to keep solar panels clean?

www.dwssolutions.co.za

📸 WE FOUND THIS ON SITE

⚠️ A burnt MC4 connector was identified during a recent fault investigation after a string stopped producing power.

MC4 connectors may be small, but they play a critical role in connecting solar modules within a string. When a connector becomes loose, damaged, or improperly crimped, resistance can build up and generate excessive heat. Over time, this can lead to connector failure and cause the entire string to go offline.

📊 Behind the Numbers
Let's put that into perspective:
While every solar installation is different, the example below illustrates the potential impact of a single string outage on a commercial solar system.
A typical 100kW solar system may have around 10 strings. If one string goes offline, that's approximately 10% of the system's generation lost.

Assuming the system produces around 450 kWh per day:
⚡ 45 kWh lost per day
⚡ 1,350 kWh lost per month
⚡ 16,425 kWh lost per year

At an electricity tariff of R3.00/kWh, that's approximately:
💰 R135 lost per day
💰 R4,050 lost per month
💰 R49,275 lost per year

And all of that can be caused by a single failed connector.

The good news? This fault was identified, the damaged MC4 connector was replaced, the string was tested, and full production was restored.

💡 Small components can have a big impact on system performance. Regular inspections help identify these issues before they become costly losses.

www.dwssolutions.co.za

☀️ TRUE OR FALSE?
You don't need to clean your solar modules in winter.

🤔 Many solar system owners believe this, but is it actually true?

Vote below: 👍 TRUE ❤️ FALSE

Then tell us why you chose your answer in the comments. We'd love to hear your thoughts and experiences

💬 Have you noticed any difference in your system's performance between seasons?

www.dwssolutions.co.za

⚠️ Most solar sites don’t suddenly fail , the warning signs are usually there long before the damage happens.

The reality is, many sites only discover serious faults once the damage has already been done, simply because annual inspections and maintenance are not being done consistently every year.

What starts as a small issue can quickly turn into:
❌ Burnt connectors
❌ Cable damage
❌ System downtime
❌ Production losses
❌ Safety and fire risks

Solar plants are major investments, and just like any critical electrical infrastructure, they require ongoing professional maintenance to remain safe, compliant, and efficient.

At DWS Solutions, we work with our clients to identify problems before they become costly failures through:
✔ Annual site inspections
✔ Preventative maintenance
✔ Corrective repairs
✔ Fault finding & diagnostics
✔ Thermal inspections & testing
✔ String and connector repairs
✔ Emergency breakdown support

A simple inspection today could prevent a major failure tomorrow. ☀️⚡
Don’t wait until your site becomes a safety risk or starts losing production before taking action. Preventative maintenance isn’t an expense, it’s protection for your investment.

www.dwssolutions.co.za

⚠️ Don’t Let Small Faults Become Costly Failures ⚠️

An annual site inspection is only the first step in protecting your solar investment. Identifying faults is important but taking action through corrective maintenance is what keeps your system safe, compliant, and performing at its best.

At DWS Solutions, our inspections often uncover issues such as:
🔧 Loose electrical terminations
🔧 Damaged DC cables
🔧 Poor cable management
🔧 Missing warning labels
🔧 Corroded earth connections
🔧 Loose clamps & mounting hardware
🔧 Inverter or string faults

Ignoring these issues can lead to:
❌ Reduced system performance
❌ Increased downtime
❌ Safety risks
❌ Expensive future repairs
❌ Potential equipment failure

Corrective maintenance ensures that identified faults are repaired before they escalate into major operational or safety concerns.
Preventative inspections combined with corrective action help maximize system lifespan, reliability, and energy production.
✅ Inspect
✅ Identify
✅ Repair
✅ Protect Your Investment

DWS Solutions
Maintain | Support | Solve
www.dwssolutions.co.za

⚡ Earthing isn’t just “another cable in the system.”

It’s one of the most critical safety and protection measures on any PV site, yet it’s also one of the most neglected items we find during inspections.

One of the most common issues we come across?
➡️ Corroded earth connections
➡️ Loose or damaged earth terminations
➡️ Failed continuity tests
➡️ Missing bonding between equipment and cable trays
➡️ High resistance on earth paths

The scary part?
A solar plant can still appear “operational” while the earthing system is compromised.

At a PV site, proper earthing is essential for:
⚡ Protecting people from electric shock
⚡ Allowing fault currents to clear safely
⚡ Reducing fire risk
⚡ Protecting inverters and sensitive equipment from surges/lightning
⚡ Stabilising system voltages
⚡ Ensuring compliance and long-term reliability

Corrosion is a silent problem.
It slowly increases resistance over time until protection systems can no longer operate effectively when needed most.
And because most earth faults aren’t visible from a monitoring platform, they often go unnoticed until a major failure occurs.
A properly maintained earthing system is not just about compliance , it’s about safety, reliability, equipment protection, and ensuring the system performs as intended for years to come.

⚠️ “Operational” does not always mean “compliant.”

This installation was operational during inspection, but one workmanship issue immediately stood out.

Can you spot it? 👀👇

A good reminder that what works in the
moment is not always the correct or safest long-term solution.

⚠️ This is what can happen when a solar site isn’t properly maintained 👀☀️

Lack of maintenance might not seem serious at first until performance drops, faults start appearing, and safety risks increase ⚡🔥

What issues do you think can develop over time from poor maintenance? Drop your thoughts below 👇

Regular inspections and maintenance can make all the difference 💡🛠️