A solar ground mount system is the core support structure of a photovoltaic (PV) array, and as such, it directly impacts power generation efficiency and safety. Long-term outdoor operation exposes these systems to challenges from environmental corrosion and mechanical stress. In addition, improper use or maintenance negligence can also compromise their smooth functioning. Therefore, ensuring efficient and stable operation is essential for maximising a solar project's return on investment. This article uncovers the common problems in ground-mounted solar systems and their solutions.

Importance of Maintaining a Solar Ground Mount System

The long-term value and return on investment (ROI) of a solar ground mount system are tied to its operations and maintenance (O&M) strategy. Without a systematic maintenance plan, the power generation efficiency of the PV array will decline significantly over time, diminishing the energy output and economic returns. A robust maintenance program provides multiple core benefits for a solar panel ground mounting system:

1. Reduce Power Generation losses

A study^[1] shows that coal dust buildup on PV panels results in a 64% reduction in output power. This is why timely inspections are critical for preventing generation loss, which enables your solar ground mounting system to continue functioning at optimal capacity.

2. Extend System Lifespan

Routine maintenance facilitates the identification and resolution of early-stage issues, such as loose fasteners, frayed cables, or the onset of corrosion. By intervening before these problems escalate, you can effectively prevent structural damage, protect the asset value of the solar ground-mounted system, and extend its designed operational life.

3. Lower Unexpected Maintenance Costs

Emergency repairs are almost always more expensive and more disruptive than scheduled maintenance. A sudden system failure, whether due to a structural issue or an electrical fault, can trigger costly and unexpected downtime, requiring rush services and replacement parts. By establishing a solid, scheduled maintenance plan, you can budget for maintenance costs in advance, avoiding the financial shock of a major breakdown.

Common Issues of a Solar Ground Mount System

During the actual operation process, solar ground mount systems may encounter various problems due to factors such as environmental conditions, usage, design, and installation. These problems can be categorised into four main types:

1. Structural Issues

Structural strength is critical for reliable operation. But external stress and installation errors often spark serious problems. 

(1) Loose Bolts and Structural Instability: The seasonal shifts or wind-induced vibrations can loosen the fasteners. This increases the risk of panel misalignment and undermines the system's stability. 

(2) Mount Corrosion: Exposure to moisture, humidity, and air pollutants often gives rise to corrosion in the solar ground mount system. This issue is more evident in coastal or industrial regions. Without protective coatings, the structural frame weakens, which affects its durability. 

(3) Foundation Settlement or Tilt: Caused by issues like insufficient foundation depth or uneven soil compaction, the foundation may settle or shift under environmental and structural loads (e.g., rain, frost heave). This displaces solar panel mounting, lowering power generation efficiency and risking structural destroy.

2. Mechanical and Electrical Issues

Electrical or mechanical components of the solar mounting system must be in good condition to guarantee optimal power output. 

(1) Inverter Failure: The inverter is responsible for converting DC electricity into usable AC power. If it fails due to overheating or component ageing, the power generated by the PV modules cannot be converted and transmitted. 

(2) Cable Damage or Animal Gnawing: During installation, over-tensioning or contact with sharp bracket edges can breach cable insulation. Furthermore, animals like rats or squirrels may gnaw on cables, exposing conductors. Such damage can precipitate short circuits, create a shock hazard, or disrupt power, jeopardising system operation.

3. Environmental Adaptability Issues

Various climates often present challenges for the smooth operation of a solar ground mount system. 

(1) Dust/Snow Cover: Accumulation of dust, snow, or pollen blocks sunlight, impairing energy production and efficiency if not cleaned regularly. 

(2) Excessive Vegetation: Overgrown grass, weeds, or nearby trees cast shadows on solar panels. In addition, some vegetation with strong roots may grow into the foundation of the system, affecting its stability. 

4. Design and Installation Deficiencies 

Even the best materials can fail if the solar ground mount system is poorly designed or installed. 

(1) Hot Spot Effect: Unreasonable module arrangement or improper installation near obstructions like trees or buildings can easily induce the hot spot effect. This not only decreases generation efficiency but may also ruin the permanent cell, severely shortening module lifespan. 

(2) Insufficient Wind Resistance: Undersized brackets, too few attachment points, or inaccurate wind load calculations can lead to panel bending or dislodgement in strong winds. Such failures can bring economic loss and introduce serious safety risks to personnel and the surrounding environment.

 

Solutions and Best Practices

1. Preventive Maintenance Strategy

To combat structural or electrical issues of a solar panel ground mounting system, an adequate maintenance strategy is essential: (1) Regular Inspection Plan: Schedule periodic inspections to ensure the structural integrity of the system. Check for loose bolts, soil settlement, or panel orientation. (2) Maintenance of Key Components: Critical components like cables, inverter, or other electrical parts need routine servicing. Monitor issues like overheating, wire cracking, or software errors. Also, mounting frames should be maintained properly for enhanced reliability.

2. Material and Design Optimisation

Core material and system design influence the overall output. (1) Corrosion Prevention Measures: To prevent your solar ground mount system from corroding, go for galvanised steel, aluminium alloys, or anti-corrosion coatings. These materials sustain strength and protect against structural degradation. (2) Wind and Snow Resistance Design: Proper engineering ensures that arrays can endure high winds or snow buildup.  Optimise tilt angles and incorporate aerodynamic designs for resilience. (3) Intelligent Monitoring System: Smart sensors permit remote tracking of performance in real-time. This enables quick detection of faults to maintain stable operations.

Get a Reliable Solar Ground Mount System from Clenergy

When it comes to selecting a reliable partner for ground-mounted solar systems, Clenergy is an excellent choice. Our products are built with high-quality materials and advanced manufacturing processes, delivering superior corrosion resistance and lasting durability. Leveraging deep expertise, our R&D specialists engineer custom solutions that fully account for regional climatic patterns, topographical challenges, and your specific needs. What's more, we provide comprehensive after-sales support, including installation guidance, maintenance training, and troubleshooting. By choosing us, you not only secure an efficient, stable, and safe PV mounting system but also benefit from reduced long-term maintenance costs and minimised risks. This ultimately translates into greater economic value and a higher return on investment.

Reference

• Available at: https://www.sciencedirect.com/science/article/pii/S2772940024000353 

About Clenergy Established in Melbourne, Australia, and extending our presence with offices and factories across China, Japan, the Philippines, Thailand, and Germany, Clenergy stands as an enabler for the public sector, enterprises, and governments in pursuit of sustainability and carbon neutrality solutions. Our commitment is grounded in a vision of a future powered by sustainable, clean energy. We persistently reinvent our approach, leveraging innovative technology and service, as we strive towards realising this mission.