9 Off-Grid Solar Safety Measures You Can’t Afford to Ignore
Anything that involves electricity can be a fire hazard — especially off-grid solar power systems that are old, DIY, or have evolved over the years (and nobody knows where the wires go anymore). Below is a pile of molten lead-acid batteries after they caught fire from a cobbled-together system.
Solar panels produce direct current (DC). It is much more dangerous than alternating current (AC), i.e., what comes out of a wall socket. As such, a solar system (especially a high-voltage one) requires a much more rigorous approach to safety.
Is your off-grid solar system safe? Here’s an 8-point checklist:
Right-size the components
Assess your energy demand and usage pattern, then dimension components like inverters and solar charge controllers (SCCs) to handle the load. Also, your cables should be of the appropriate gauge to prevent overheating and fire risks.
Use high-quality parts
Select inverters and SCCs suitable for off-grid systems. They should include built-in safety features like overload protection and surge suppression. Meanwhile, your solar panels should be able to withstand environmental conditions — for example, we source utility-grade panels that can weather the harsh climate (like high UV) here in Caliente.
This is cheap copper-clad aluminum wire (CCA). It’s not as durable and prone to corrosion. It also creates more heat (i.e., a fire hazard).
Mount your panels securely
We’re a big fan of ground-mounted solar panels because they’re cheaper to implement, easier to maintain, and give you more opportunities to maximize power production. Still, be sure to secure the panels even if they’re close to the ground. Severe wind gusts may lift the panels, creating hazardous flying objects and projectiles.
Implement electrical safety measures
Install fuses and circuit breakers to protect the system from overcurrents and short circuits. Use surge protectors to guard against voltage spikes caused by lightning or other power surges. Also, you should have mechanisms to disconnect the DC and AC sides of the system during maintenance or in emergencies.
We’ve seen many dangerous installations. The wiring box in this pump house has exposed copper conductors. There was 245v measured between these terminals — an electrocution risk. Having the pump guy do the job of an electrician often doesn’t end well.
Beware of low-quality safety parts. Worse than having no safety measures, they give you a false sense of security. Don’t buy cheap parts off Amazon, please.
Ensure proper grounding
Properly ground all equipment with grounding rods and/or lightning arrestors to protect against electrical faults and lightning strikes. Grounding prevents static electricity buildup and minimizes the risk of electric shocks.
Choose a safe battery chemistry
We’re a big fan of lithium iron phosphate (LFP) batteries because they’re intrinsically safe. LFP is the most stable chemistry available and least prone to thermal runaway. On the other hand, lead-acid batteries often lack adequate safety measures. They’re also prone to leaking toxic chemicals. (And they’re more expensive than lithium batteries!)
Don’t skimp on batteries
Batteries have the most potential to catch fire in a solar system. Buy high-quality lithium batteries (i.e., not the cheapest ones from Amazon) with protection circuitry. Sometimes, we custom-program battery management systems (BMSs) for our customers to prevent overly deep discharges and augment the safety profile.
Install thermal sensors
LFP batteries won’t charge when the ambient temperature is close to freezing, and they die. Lead-acid and lithium-ion cobalt batteries could melt and catch fire when they get too hot. No matter what batter chemistry you use, you should have the appropriate thermal sensors and BMS to prevent thermal events.
Perform regular maintenance
Regularly clean your solar panels with soap and water to maximize power production. Also, inspect cables and connectors for wear, tear, or corrosion and replace them as necessary. Critters like rabbits and squirrels may chew on exposed wiring, so you should have proper ducting to protect the components.
Connections may get loose over time, and metal in wires may oxidize — leading to increased resistance and fire hazards. Using anti-oxidant paste during installation can minimize the risks.
A safety check or upgrade for your existing solar system
Get in touch to schedule an onsite visit during which we’ll evaluate your current setup, recommend safety improvements, and help you implement the proper measures.
