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Thermal Imaging — Seeing What the Eye Can't
An infrared (IR) camera detects temperature differences on panel surfaces. A healthy panel operating under uniform irradiance should be uniformly warm. Any abnormally hot region indicates a point of electrical power dissipation — either a hotspot (shading, cell fault) or a high-resistance connection (poor crimp, corroded contact). Thermal imaging is the fastest and least invasive way to survey a large array for faults.
Common Thermal Fault Signatures
Thermal Pattern | Fault Type | Severity |
|---|---|---|
Single cell hot (1–2°C above rest of panel) | Cell micro-crack or internal defect | Low — monitor; plan replacement at next opportunity |
Single cell very hot (>20°C above rest) | Hotspot — potential bypass diode failure or heavy shading point | High — investigate immediately; fire risk if sustained |
One bypass diode group hot (one-third of panel) | Cell group shaded or bypass diode failed short-circuit | Moderate — locate and remove shading source or replace panel |
Entire panel hot relative to neighbours | String current mismatch — panel degraded or cracked | Moderate — check with I-V curve tester |
Hot junction box on panel | Internal connection fault in junction box | High — junction box may need replacement |
Hot connector point (in-string) | High-resistance MC4 connector — partial mating or oxidised contact | High — arc fault risk; replace connector immediately |
Thermal Imaging Best Practices
Survey during periods of high irradiance (>700 W/m²) with panels near maximum operating current — low irradiance reveals fewer faults
Survey from the roof (not the ground) for best resolution on individual cell-level faults
Record GPS coordinates or panel grid position for each fault found
Compare consecutive annual thermal surveys — trending hotspot severity identifies panels approaching failure before they fail
Engr. Jason Morales — Founder, SolarEnergyPH
