Thermographic surveys from Quayle Industries can pinpoint developing faults in solar panels for repair before there is visible damage, a loss of electricity generation or, in the worst cases, fire
With the growth of solar panels being installed in both commercial and
domestic properties, with 1.8m panels installed up to August 2025, there has
been a rise in fires involving solar panels by 60% since 2022.
These can be due to several root causes, incorrect installation is listed as the most common reason, with loose connections, damaged or faulty wires being put in from the start, which can lead to arc faults or other electrical issues.
As well as these issues, defective components, high currents and environmental issues can all play a part in solar panels failing and in the worst situations, igniting.
Thermography is the technique of using thermal sensors to visualise the infrared radiation, or heat patterns, that are emitted from all surfaces. It is a nondestructive method of assessing temperatures and identifying hidden issues, and is widely used in engineering, medicine and in building surveying. It is a predicative maintenance tool that can detect problems within the solar panels and its associated components, while they remain operational.
A thermographic survey can detect module and cell hotspots. If a solar cell is cracked,
damaged, shaded or working incorrectly, it can stop efficiently generating power and instead that energy is turned into heat. A thermal survey can detect several issues, such as:
- Hot cells, or groups of hot cells.
- Cracked cells.
- Damaged cells.
- Dirt of shading that has been affecting an area.
- Faulty connections.
- Junction boxes that are hotter than they are designed for.
If issues like the above are left, they will damage the materials that make up the
panel, can affect the insulation and, in the worst situations, increase the risk of a fire.
However, that is purely looking at the panels themselves, it is often the wiring and electrical connections that are the biggest risk of fires occurring.
Loose, corroded, incorrectly fitted or mismatched connections create a resistance in the system, and that resistance leads to a build-up of heat. Using a thermal sensor,
these hotspots can be found in the system, which would be missed if carrying out a
visual inspection.
It compares the connections and can help identify any that are significantly hotter than
the ones around it carrying the same current. Once they are identified, they can be isolated
and repaired before the insulation melts, allowing the current to arc and igniting the
materials around it.
A sensible approach to solar panel maintenance is to know that the equipment is correctly fitted to start with, then monitor it for any anomalies that may occur:
- Baseline: A thermal survey once the system is commissioned will highlight any components that have not been correctly fitted and will allow the normal operating temperatures to be understood and noted.
- Maintain: Carrying out a thermal survey periodically will identify any new anomalies
or known anomalies that are becoming worse. - Identify: Any rapidly changing temperatures require further investigation to pinpoint the root cause of the issue.
- Electrical Investigation: Confirm the cause using standard electrical techniques, including testing of current, voltage, insulation and connection checks.
- Repair: Once the component has been replaced, repeat the survey to confirm the thermal anomaly has disappeared and the system is working correctly.
This predictive maintenance approach allows developing faults to be identified and repaired early, rather than waiting for an inverter alarm, visible damage being noticed,
electrical generating being reduced or, in the worst cases, fire.
Predictive maintenance is often the most cost-effective way to maintain a system. As the old saying goes, a stitch in time saves nine!
Quayle Industries offers thermal surveys as part of our core services. When approaching
a bank of solar panels, using radiometric drone-mounted thermal sensors allows a lot of panels to be surveyed, especially if they are located on a roof or other hard to reach location.
This is supplemented by using handheld sensors to examine inverters, connections
and junction boxes to give a full picture of the system, not just the panels. Quayle Industries also offers other drone services, primarily for commercial clients, including 3D mapping, LiDAR scans, roof inspections and mapping, as well as commercial videography for construction and infrastructure projects.
The post Thermographic surveys: Predictive maintenance for solar panels appeared first on Planning, Building & Construction Today.
