Maybe it’s corrosion, broken glass, micro-cracks, loose connectors, or a faulty inverter that led you to search for the most common solar panel repairs and how to fix them. Or maybe you don’t have the slightest clue why your solar panels are underperforming and are just trying to diagnose the problem.
On average, it takes about 10 years for solar panels to pay for themselves. You want to make sure you are getting the most from your investment, so if your solar panel is not performing at max efficiency, you need to know why and how to fix it.
What Are Solar Panels?
Solar photovoltaic panels are technological equipment that absorb sunlight and transform it into usable electricity. They are typically placed on top of roofs where they get a lot of sun exposure. There are three types of solar panels:
- Monocrystalline. Monocrystalline panels are the most expensive, highest quality, and the longest lasting. They have a 24% energy conversion rate.
- Polycrystalline. With an energy efficiency rate of 20%, polycrystalline panels are less expensive but not as high quality as monocrystalline.
- Thin-Film. Lightweight and mobile, thin-film panels have an energy efficiency of 19%.
The appeal of solar panels is that they save money on energy bills and are a renewable energy source. With lifespans of 25 to 30 years, they are designed to withstand harsh weather conditions such as:
- Hail
- High winds
- Hurricanes
- Rain
If your solar array is large enough, it is possible to go off-grid and have your entire home powered by solar energy. Solar batteries are an additional solar system component that can store excess energy.
What Causes Solar Panels to Break
Solar panels are weather resistant and built to withstand up to 140 mph wind gusts. But although they are hardy and durable, solar panels are not impervious to all damage. Many things can harm a solar panel:
- Cracks
- Dirt and sand
- Wind
- Water
- Overheating
- Lightning
- Fires
- Hail
- Snow and ice
- Falling tree branches
- Vandalism
- Stray balls thrown on the roof
- Animal damage
The most common problems are cracks, broken glass, and loose wire connections. Solar panels are protected with tempered glass, the same substance used to protect a car’s paint job.
How to Repair Broken Solar Panels
It’s good to know what causes solar panels to break and what to look for. Repairing solar panels is not a DIY job. You need a professional who is skilled in solar panel repair who can properly diagnose and fix the problem. Also, not using a professional can void your warranty.
Cracked Panels
Solar panels have tempered glass, which is stronger and more durable than normal glass. With a glass surface, it is little surprise that solar panels are susceptible to cracking.
If the seal of the panel is cracked, water and dust can get inside the PV system. Water and electricity don’t mix and can cause electrocution or fires. Dust will damage your solar panel and could lead to circuit failure.
There are many potential culprits behind broken solar panel glass:
- Hail
- Falling tree branches
- Extreme temperature changes
If you pour cold water on hot panels it will crack the glass. Conversely, if you pour hot water on cold panels, the temperature difference also will crack the glass. That is why you should always use lukewarm water to clean solar panels.
Glass is a very important component of a solar panel, as it shields the PV cells underneath. Luckily, even with cracked glass, solar panels should be able to still perform efficiently in most cases. If only a portion of the glass is broken, a solar panel can still produce solar energy.
However, if the glass is cracked, several problems arise:
- It exposes the delicate module components to the weather.
- Dirt buildup gets trapped in the crack and deteriorates the system.
- Water and moisture can leak into cracks.
Due to the way a solar panel is constructed, the glass is attached to the solar cells underneath it, so you can’t simply replace the glass when it cracks. If the damage is severe, sometimes it’s cheaper to buy a new panel instead.
If a large portion of the glass has been shattered or cracked, then homeowners have to replace the whole panel since the extensive damage makes it too difficult for the solar panel to perform properly. Sometimes glass is so expensive, it’s cheaper to buy a new solar panel than replace the broken glass.
Stained Glass Tape
If your solar panel has a minor crack, you can use stained glass tape to reattach the broken parts.
Another solution is to use sealant tape, which is available at most hardware stores. Make sure that the sealant tape you use is designed for outdoor use.
Transparent Laminating Film
Laminating films are a simple fix for broken solar panel glass. To apply a transparent laminating film onto a solar panel:
- Stick the laminating film to the edges of the solar panel using a heat gun or glue gun.
- Apply the film carefully to avoid wrinkles. Any folds or wrinkles in the material could let water in.
When finished, it should be watertight and sealed so that nothing can leak inside the PV system.
Polyurethane Layer
Polyurethane is the popular option for repairing cracked solar panels, although you also can use other resins such as an epoxy, as long as it’s waterproof.
Follow these steps to apply a polyurethane layer or any kind of waterproof resin layer onto your solar panel:
- Before you apply resin to your panels, you should first wash your solar panels and dry them off.
- Follow the package directions on how to mix the resin in a bucket.
- Pour the resin mixture over the panel.
- Use a brush or similar tool to spread the resin mix evenly over the solar panel.
- Wait for the mixture to dry on your panel.
- Once dried, the mixture will have created a transparent, waterproof layer that will protect your solar panel from dirt, water, and other damaging contaminants that might try to worm their way into your solar panel.
When you install the layer over your solar panel, the key is to make sure there are no wrinkles or creases, otherwise this will ruin the protectiveness of the polyurethane layer.
The problem with a polyurethane layer is that it is only a temporary fix. Over time it will peel off and come up around the edges, especially if it isn’t applied evenly.
Micro Cracks
Regular cracks are easy to spot, but micro cracks are invisible to the naked eye. Although you can’t see these minuscule cracks, they pose a real danger to your PV system. Micro cracks are typically a problem in low-quality solar cells.
If you find traces of snail trails on your solar panels, it may be a sign of micro-cracks on your panel’s surface.
Solar panel manufacturers offer product warranties that cover micro cracks if they damage your solar modules.
If necessary, micro cracks can be fixed in the same way that regular cracks are repaired: use stained glass tape or cover them with a polyurethane layer or transparent laminating film.
Corrosion
If you allow corrosion to build on your solar panels, eventually you’ll have to replace an entire section of the solar panel. Internal corrosion occurs when moisture seeps into the interior of the solar panel, rusting the internal components of the solar module.
If you deal with corrosion as soon as you spot the issue, you will be able to prevent its destructive effects. Typically, the internal components that most often need replacing are the sockets and connectors.
To get rid of corrosion, scrub off the rust with brushes and specialized cleaning products. Do not use regular soap since that leaves behind a residue.
Delamination
Delamination is when laminated solar panel components detach and are no longer connected to each other. It results in panel corrosion and eventually causes the solar panel system to fail. Bubbling on your panels may be a sign of delamination.
Several things can cause delamination:
- Bad workmanship
- High temperatures
- Low-quality panels
Delamination occurs most frequently in tropical climates where it’s warm year-round.
There isn’t a way to repair your solar panels if they are affected by delamination. If they begin to show signs of delamination, they will have to be replaced.
Degradation
Degradation is the amount by which a solar panel’s output rate decreases incrementally each year. From the minute it’s installed, a solar panel’s efficiency rate incrementally decreases over time. Degradation is caused by aging and weather exposure.
As a solar panel ages, it is inevitable that its efficiency will decrease over time. Solar panels suffer a performance loss of 0.25% to 0.8% a year. This is a natural effect of the modules aging and there isn’t anything that can be done to prevent it.
Once a panel’s efficiency drops too much, it eventually will need to be replaced. Typically, solar panels should be replaced 25 to 30 years after its installation. By the time a panel reaches 25 years, it will only be operating at about 80% of its original efficiency.
The PID effect, or potential-induced degradation, is damage that occurs due to voltage fluctuations between the cell and other components of the module. The potential difference causes voltage leaks and ultimately reduces solar energy output and causes panel failure.
In simple terms, the PID effect is a sign of aging solar panels. High temperatures and high humidity levels worsen the PID effect.
Hot Spots
Although their job is to absorb heat, panels can develop hot spots. Hot spots are when a portion of the panel overheats, which damages the panels.
Hot spots cause the system to dramatically decrease in energy output. The panel may even stop producing solar power altogether. Hot spots cause the device to age more quickly, overall shortening its lifespan.
Hot spots can be caused by many different things:
- Delamination
- Micro cracks
- Bad handling during shipping
- Extreme changes in temperature
- Poor module production
- Some weather conditions
- Dirt buildup
Most of the time you won’t be able to detect hot spots with the naked eye, although sometimes they are identifiable as brown spots.
To avoid hot spots, homeowners should ensure their panels have enough airflow and ventilation beneath them in order to cool the PV system and keep it from overheating.
Regularly cleaning your solar panels can prevent hot spots from occurring, since dirt buildup can cause hot spots. To clean your solar panels you can hire a professional solar panel cleaner, DIY, or install automatic cleaning robots.
Snail Trails
Despite the name, snail trails are not tracks left behind by snails crossing over the surface of a panel. In fact, they have nothing to do with snails at all.
Snail trails, a sign of corrosion, are brown lines that leave stains on the surface of your solar panel. The stains block the solar cells from absorbing sunlight, which slows down solar energy production.
Micro cracks cause snail trails if moisture seeps into the solar panels.
To prevent snail trails, you can repair the panel by applying a protective transparent resin to the surface of a panel. Always handle the panels with care to prevent micro cracks.
Lightning
They say that lightning never strikes in the same place twice, but it’s bad enough when it’s just once. Lightning strikes melt the solar panel and wiring, and the melted solar cells can start a fire.
If your panel has been struck by lightning, there may not be anything you can do to fix it. Solar panels that have suffered lightning strikes are generally damaged beyond repair.
To decrease the chances of lightning striking your panels, don’t install your solar panels near trees, especially if you live in an area that receives a lot of lightning storms.
In the event your solar panels are damaged by a lightning strike, call an expert to assess your solar panels and see if they are salvageable or beyond repair.
Improper Installation
Proper installation is critical. If a solar panel isn’t properly installed, it will lead to a lot of problems later on.
Improperly installed solar panels aren’t able to withstand rough weather conditions, as they can be harmed by fierce winds or heavy rainfall.
Loose Wiring
Wire cables connect the PV cells to the solar inverter and solar batteries. The wires should be snugly secured to each solar cell. Poorly connected wires lead to loose connections and wiring problems that reduce the panel’s overall energy output.
Loose wires should be repaired by a licensed electrician. Fixing a solar panel’s wiring requires technical experience, and it isn’t a safe or easy feat for untrained beginners.
Fixing a loose connector involves cutting inside the solar cells’ silicone. Once the cells are exposed, the wiring can be accessed so that a technician can fix any loose connections.
Loose wire connections are typically a sign of poor installation, jostling, or module damage. If your solar panels are having trouble performing for that reason, chances are they were not installed correctly.
Inner Module Damage
It’s not just the external components of a solar system you have to watch out for, but the module’s internal workings, as well. The internal components produce electricity and run the whole operation.
Inner module damage is often caused by faulty production or poor quality components. This kind of damage results in:
- Delamination
- Snail trails
- Cell discoloration
- Solar connector discoloration
- Yellowing sheets
- PV cell staining
- Burnt solar cells
A halt in electricity production is likely a sign of electricity production, so if your solar panels stopped producing energy, you may need to replace blown fuses, switches, or circuit breakers. Any broken wires or loose connectors will need replaced or fixed as well.
If you notice that your solar cells are off-color or stained, it’s a sign of internal system damage.
Damaged or cracked solar panels mean it’s game over for your solar panels. Solar panels are designed so that the glass will protect the cells from external elements. So if your solar cells are damaged, it means you will have to replace the panel.
Solar Inverter Maintenance
Solar inverters are an important part of the solar panel system, as they are the device that transforms collected sunlight into usable electricity. They typically last 10 to 15 years before they have to be replaced. Generally, you will have to replace your solar inverter at least once during the lifetime of your solar panels.
Watch for signs your solar inverter isn’t working properly and needs maintenance:
- Electric bill is higher than normal
- Error message on screen
- Light is yellow, red, or flashing
- There is no light
- Inverter is disconnected
- Solar battery isn’t charging
A solar panel can overheat or suffer performance issues if the inverter is not installed correctly.
Solar inverters also suffer from isolation faults. Isolation faults occur when different parts of the circuit have a short circuit. These short circuits can be caused by:
- Sleeve damage
- Moisture
- Improper installation
- Bad DC connection
Never try a DIY repair job on your solar inverters. Always hire a professional to fix the inverter. Solar inverters require a lot of technical knowledge to fix, and if you don’t have the know-how to fix it, you might end up damaging the inverter more than repairing it.
How Do You Know Your Solar Panels Are Damaged?
A significant decrease in solar panel performance or solar modules malfunction is an indicator your solar panels are damaged.
Schedule a regular inspection for your solar panels to check for faulty wiring, cracked glass, fractures in the system, and other possible damage.
Monitor your solar panels’ performance; a significant drop in their performance may indicate a problem beyond typical degradation. You can monitor your solar panels with a mobile app on your phone that will update you on the status of their energy output.
However, not all significant decreases are caused by solar panel damage. If a solar panel is dirty, it can decrease its energy output by 10% to 30%.
Can a Broken Solar Panel Still Work?
A solar panel can continue producing renewable energy even with minor scratches and cracks. Sometimes damaged panels can still work; it all depends on the type and extent of the damage.
Even if a solar panel works after breaking or cracking, it won’t continue to function for long without repairs and will eventually stop working altogether.
Some reasons damaged solar panels need to be repaired:
- Dirt and other debris may seep into cracks and cause PV system failure
- Cracked panels produce solar power at a slower rate
- Damaged panels continue to deteriorate until they’re beyond repair
- If a crack damages the interior components, the module won’t function
- Moisture seeping into unsafe cracks can cause fires or electrocution
- A single damaged panel can decrease performance of the entire solar array
A damaged solar panel doesn’t have to be fixed immediately. But without receiving maintenance soon, the damage will get worse over time until the solar panel is no longer functional and is beyond repair.
If the scratches are just an eyesore, you don’t have to repair your solar panel.
Consider the age of your solar panel. If your solar panel is near the end of its lifespan and has suffered a lot of damage or is underperforming, it’s probably time for you to replace it instead of repair it.
Cost to Repair Broken Solar Panels
If a solar panel is fractured or cracked, the solar panel installation company should cover the repairs and replacements. On average, the prices of solar panel repairs are between $250 to $1,700.
How much solar panel maintenance costs depends on the issue your solar panel has and how difficult it is to fix. More severe problems such as inverter repairs or roof leaks take longer and cost more to replace. Simpler problems such as cracks, loose wiring, and corrosion are easy to fix and won’t cost as much.
Who Covers the Cost of Solar Panel Repair?
Solar panels are often covered by the homeowner’s insurance policy, so the insurance company might cover the cost of solar panel repairs for you. The downside is that most insurance companies require a deductible for claims, which usually costs between $500 and $2,000.
Often warranties will cover the cost of your solar panels, though you may have to pay a fee. Warranties typically cover your solar panels anywhere from 10 to 25 years, so check what your warranty covers before you pay for the repairs out of your own pocket.
Purchasing a new solar panel always costs more than repairs, so you’ll have to do a cost-benefit analysis to determine if the repairs are worth it.
Also, consider how much life your solar panel has left and if it’s worth trying to repair it. If the repair costs just as much as replacing your solar panel, then you would be better off buying a new one and skipping repairs.
FAQs About How to Repair a Broken Solar Panel
Yes. If only one solar panel has been damaged, it’s best to repair the panel and replace the necessary components, if possible. If that isn’t an option, you can instead replace the lone panel that is broken. You don’t have to replace an entire solar array if only one solar panel is broken.
Yes. There are many benefits of cleaning solar panels, so homeowners should clean their solar panels a minimum of one to two times a year.
Solar panels work just as well in the wintertime as they do other times of the year. In fact, sometimes solar panels produce more solar power during the winter months than in warmer seasons.
Repair Your Panels Now Before They Need to be Replaced
There are lots of things that can damage a solar panel. Sometimes it’s the rough weather and sometimes it’s just the unavoidable effects of aging. Whatever the source, make sure your solar panel gets the maintenance it needs before the damage is beyond repair.
If your solar panel is busted and needs some TLC, don’t hesitate to find a solar panel mechanic near you.
Main Photo Credit: Pexels
