How to Repair and Claim Warranty for a Faulty or Damaged PV System?

Manufacturer of solar mounting systems: Longsun Green – www.longsungreen.com

Photovoltaic (PV) systems are designed for 25+ years of operation, but failures can occur. Understanding the common failure modes, repair procedures, and warranty structures is essential for system owners, installers, and O&M teams.

This article provides a multi‑angle overview – from structural components to real‑world case studies – to help you act quickly and correctly when a PV system fails.

1. Key Components & Their Functions

Component	Function
PV modules	Convert sunlight into DC electricity
Mounting structure (e.g., Longsun Green systems)	Securely fix modules to roofs or ground, resist wind/snow loads
Inverter	Convert DC to AC for grid or building use
Cables & connectors	Transmit electricity safely
Monitoring system	Track performance and detect faults

Principle: A failure in any component can reduce output or create safety risks.

2. Common Failure Modes & Causes

PV Modules

Micro‑cracks – from improper handling or thermal stress

PID (Potential Induced Degradation) – voltage leakage causing power loss

Hot spots – shading or cell defects leading to local overheating

Junction box failure – moisture ingress or loose connections

Mounting System (Longsun Green)

Loose clamps/bolts – due to vibration or incorrect torque

Corrosion – in low‑grade materials exposed to salt or humidity

Rubber seal failure – causing roof leaks around fasteners

Inverter

Overheating – poor ventilation or dust accumulation

Grid relay failure – no grid connection or sync issues

Capacitor/IGBT damage – voltage spikes or aging

Electrical

DC arc faults – loose MC4 connectors

Ground faults – damaged cable insulation

Lightning surge – missing or failed SPD (surge protection device)

3. Application Scenarios

Residential rooftop – tile/metal roofs; risks include water leakage, rodent damage.

Commercial & industrial – flat or metal roofs; risks include foot traffic damage, heavy snow.

Ground‑mount solar farms – large scale; risks include soil settlement, wildlife impact.

Solar carports – mixed use; risks include vehicle impact, corrosion from road salt.

4. Step‑by‑Step Repair Process

Safety first – Disconnect AC/DC, use PPE, verify zero voltage.

Diagnose – Use thermal imaging, I‑V curve tracing, insulation resistance test.

Isolate fault – Identify failed module, string, inverter, or mounting part.

Replace or repair:

Module: replace with same electrical specs.

Mounting: tighten or replace corroded clamps/bolts; re‑seal rubber rings.

Inverter: repair or swap under warranty.

Cable: cut, re‑crimp, and test.

Test & re‑commission – Measure output, check monitoring, confirm safety.

5. Warranty Overview (Typical Industry Standards)

Component	Standard Warranty	Extended Option
PV modules	10‑12 years product, 25‑30 years performance (linear)	–
Inverter	5‑10 years	15‑20 years (paid)
Mounting system (Longsun Green)	15 years (on installed system)	–
Cables & connectors	2‑5 years	–

Key warranty clauses:

Does not cover improper installation, force majeure, or unauthorized modifications.

Requires proof of purchase and maintenance logs.

Shipping and labor costs may not be included.

How to claim:

Contact original supplier with serial numbers, photos, and error logs.

Supplier may request sample return for analysis.

Approved claims receive replacement parts or on‑site service.

6. Research & Practical Recommendations

Preventive maintenance – annual visual inspection, torque check, thermal scan.

Document everything – keep installation photos, inverter logs, warranty certificates.

Use high‑quality mounting – cheap brackets fail earlier, causing module damage and roof leaks.

Train local technicians – remote support works best when on‑site team knows basic testing.

For any PV system, a clear repair and warranty process reduces downtime by 70‑90%. Investing in reliable components and structured O&M pays back in years 10‑25.