Author Topic: DIY photovoltaic array repair (lightning strike)  (Read 2593 times)

Nords

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DIY photovoltaic array repair (lightning strike)
« on: April 20, 2016, 03:08:37 PM »
(I've edited the title to reflect the cause of the problem.)

I've written about our photovoltaic array before, and here's a post with photos:
http://the-military-guide.com/extreme-home-improvement-diy-photovoltaic-array/

We first flipped the switch in early 2005, and we've upgraded it several times.  HECO's electricity sells for 30 cents/KWHr so (along with federal & state tax credits) the array paid for itself by 2010.  I had to replace the inverter last year (http://forum.mrmoneymustache.com/do-it-yourself-forum!/fixing-a-10-year-old-photovoltaic-grid-tied-inverter/), and the modern 4000-watt SMA "SunnyBoy" has worked great.

Over the last 3-4 months our photovoltaic array seemed to be declining in output.  (Why, yes, I *have* tracked monthly production logs for the last decade.  Doesn't everyone?)  Hawaii's winter months have a lot less sunshine, our vog varies dramatically over the year, and generation can fluctuate by as much as 25%.  But when output dropped another 20% (and our monthly electric bill "spiked" to $42) I knew we had a problem. 

Dammit.  I hate troubleshooting nearly 600v DC at 2-3 amps.  Solar repairs are best done at night.  With rubber gloves, rubber-soled shoes, and one hand in your pocket.

The weakest part of any array is the inverter.  I methodically measured voltages and checked those connections.  The inverter turned out to have its own operating idiosyncrasy, which set me back a day reading the documentation.  ("That's not a bug, that's a feature.")  But when one string of panels wasn't working at all, I had to get up on the roof to check those wires.  Eventually I walked by this panel and thought "Hunh."

I'm not an electrical engineer, but I think I can diagnose the heck out of the symptoms in these photos.

The panel next to it has a few scorch marks too, so I pulled both of them and jumpered across the gap.  The rest of the array is back in operation, although one string's about 34 volts lower...

In 2004 we bought 20 of these used panels, and I think they were made in 1999.  By today's standards a 55-watt panel is Stone Age tech, but the other 18 panels are still chugging along.  I'm going to drop in on our local solar supplier to ask whether they've seen this before, but I think the long-term solution is replacing the remaining 18.  The other 25 panels, rated from 50-115 watts, look fine.   

Replacing the panels won't take much effort.  A Craigslist seller has posted a 300-watt panel for $250.  At this rate I can buy them one at a time, replace our old 55-watt panels five at a time, and precisely match our production to our consumption...
« Last Edit: May 15, 2016, 12:08:07 PM by Nords »

zolotiyeruki

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Re: DIY photovoltaic array repair
« Reply #1 on: April 20, 2016, 03:32:19 PM »
Wow, that's...impressive!  Something drove too much current through that panel until it went kablooie. 

BTW, since you're up to date on it, what's a typical price for, say, 2kW worth of panels and a grid-tie inverter to match? Assuming a DIY install, naturally.

BDWW

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Re: DIY photovoltaic array repair
« Reply #2 on: April 20, 2016, 03:38:10 PM »
I'm obvious not the OP, but a 2kw system installed yourself should run around $4k.

Nords

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Re: DIY photovoltaic array repair
« Reply #3 on: April 20, 2016, 04:55:36 PM »


Wow, that's...impressive!  Something drove too much current through that panel until it went kablooie. 
I've never seen it before, either.  At first I thought a rock had cracked the glass and shorted a cell.  However it seems possible that something shorted first.  (And heated, and slagged, and then cracked the glass).  Other panels are showing a small blister in the coating on the back panel, but I don't know if I have 18 more problems waiting to happen or whether these two were an unfortunate yet isolated incident.

Has anyone else ever seen this happen to a panel?

BTW, since you're up to date on it, what's a typical price for, say, 2kW worth of panels and a grid-tie inverter to match? Assuming a DIY install, naturally.
I'm obvious not the OP, but a 2kw system installed yourself should run around $4k.
Yep.  That depends on a bunch of factors and how comfortable you are with assessing used gear.

You could plunk down a credit card in a solar-supply store (or website) for about $1/watt in panels.  Around here, though, we're seeing used modern panels for a little less.  Older used panels would be about 50 cents/watt.

You could figure out your own mounts & racks, although the commercial mounts (with flashing) and racks (with clamp hardware) are pretty slick.  At retail that'd be another $500-$1000, although tile roofs or standing-seam metal roofs have their own mounting challenges.

The inverter could either be microinverters (one per panel) or a string inverter (600 vDC per string, with an upper limit on kilowatts).  A year ago my 4000-watt Sunny Boy was $2800 (+ extra for some feature upgrades).  A 2000-watt inverter might be under $2000 but... it's limited to 2000 watts.  Almost everyone I know who's bought an inverter wishes that they'd bought a bigger one, or at least done it with microinverters (despite their flaws and expense).

You could buy a good used inverter from someone you trusted.  However you might want the manufacturer's warranty for the first year, and that's worth paying full retail.  A random Craigslist inverter could've easily been stolen from someone's garage wall.

Add in a few hundred bucks for conduit, wires, connectors, grounding straps & clips, and interconnect hardware to the subpanel breaker by your electric meter.

Grid-tied means no batteries, charge controllers, or other infrastructure.  However to arrange a grid-tied net-metering agreement with your local utility you'd need a construction permit (with fees).  The net-metering application would need to be signed by a licensed electrician, who'd also charge some fees for their signature.  (You'd have to also do everything to their interpretation of code.)  Depending on your local codes & laws, that might be a few hundred bucks for each.

You'll get about 30% in federal tax credits, which are not refundable but can be carried forward.  Then you might have additional state, county, and utility credits. 

Keep in mind that this will not add resale value to your property, although it may boost your assessed value for property taxes.  Homebuyers still will not do the math on the net present value of a PV system, and they'll ignore it when they figure out how much they want to pay for your home.  You're in it for the payback, the inflation hedging (if any), and recharging your electric vehicle.

MasterStache

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Re: DIY photovoltaic array repair
« Reply #4 on: April 26, 2016, 11:16:19 AM »
Yep that will do it.

When I installed our array in 2012, I went with microinverters. They were a bit more expensive but they are easy to troubleshoot individual panels by simply logging online to my array. I also had alerts set up to alert me if something out of the ordinary was happening (panels not producing, etc.). Plus my neighbor refused to cut down his 40' pine tree that shaded half my panels in the late afternoon. So the microinverters made since.


Nords

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Re: DIY photovoltaic array repair
« Reply #5 on: May 15, 2016, 12:06:51 PM »
I've been passing around photos of the panel, and we figured it out:  lightning strike.

The panel's label rates its current-carrying capacity at six amps.  (On a sunny day, I routinely see 3-4 amps DC from each string of panels.)  A friend was watching a YouTube video about battery connectors (hey, he's a good friend and a smart guy), and the video showed a connector failing under a 6A load.  It just vaporized without producing a lot of heat or shock, and he wondered why my panel's safety glass would shatter.  What could put more than six amps through the panel?  Once he thought of the word "lightning" a quick Google Images search showed similar symptoms.

The damage happened between 9 February - 8 March 2016.  We were home that month, but we must have been out of the house.  I remember a week of wet & rainy weather in mid-late Feb (just before the Aikau big-wave competition) and I remember watching a lot of lightning storms around the island.  But we didn't hear anything.

It's a good thing that the panels, rails, and inverter are solidly grounded!