POP Module 2 - Troubleshooting

Solar Power Systems and Energy Management

Master solar power fundamentals, battery management, troubleshooting, and sustainable operation of off-grid POP systems

Learning Objectives

By the end of this module, you will be able to:

Explain how solar panels, batteries, and controllers work together
Diagnose and resolve common power system issues
Calculate power budgets for POP equipment loads
Describe sustainability benefits of solar-powered POPs
Monitor battery charge levels and interpret system health indicators

Troubleshooting Power Issues

Common problems, diagnostic steps, and solutions

 

Most power system issues can be diagnosed and resolved in the field with basic troubleshooting. Understanding common failure modes and systematic diagnostic approaches will minimize downtime.

 

POP Troubleshooting Guide

Power System Diagnostics & Solutions

PROBLEM

POP Equipment Offline / No Power

Possible Causes

  • Battery completely discharged (SOC 0%)
  • Charge controller in protected mode
  • Loose or corroded connections
  • Blown fuse or tripped breaker
  • Equipment enclosure power switch off

Diagnostic Steps

  1. Check equipment enclosure power switch (should be ON)
  2. Verify battery voltage at terminals (should be ≥11.5V for 12V system)
  3. Check all fuses and breakers in power distribution panel
  4. Inspect battery cable connections for tightness and corrosion
  5. Access Cerbo GX (if powered) to check for error codes
  6. Verify solar panel connections and check for physical damage

Solutions

  • If battery voltage <11V: Allow solar charging for 4-6 hours, or jump-start from vehicle
  • If fuse blown: Replace with same amperage rating, investigate cause of overcurrent
  • If connections loose: Tighten with appropriate wrench, apply dielectric grease
  • If corrosion present: Clean terminals with wire brush and baking soda solution
PROBLEM

Batteries Not Charging

Symptoms

  • SOC decreasing during daylight hours
  • Cerbo GX shows 0W solar production on sunny day
  • Battery voltage not increasing during day

Diagnostic Steps

  1. Verify solar panels are not shaded (trees, mast, equipment)
  2. Check solar panel surface for heavy dust/dirt accumulation
  3. Inspect solar panel cables for damage or disconnection
  4. Verify charge controller displays incoming solar voltage
  5. Check for error codes on charge controller

Solutions

  • Remove shading sources or reposition trailer
  • Clean solar panels with water and soft brush (no abrasives)
  • Reconnect or replace damaged solar cables
  • Reset charge controller (power cycle) if necessary
  • Contact IT support if charge controller appears failed
PROBLEM

Rapid Battery Discharge

Symptoms

  • SOC drops faster than expected (e.g., 50% to 20% overnight)
  • High current draw shown on Cerbo GX (>10A continuous)
  • Batteries don't last through night

Possible Causes

  • Additional equipment connected (cameras, sensors) drawing unexpected power
  • Failed equipment with short circuit or excessive draw
  • Degraded batteries with reduced capacity
  • Inverter left on powering AC loads

Solutions

  • Review Cerbo GX load monitoring to identify high-draw equipment
  • Disconnect non-essential loads one at a time to isolate problem
  • Verify inverter is off when not needed (check equipment enclosure)
  • If batteries are >5 years (SLA) or >10 years (LiFePO4), may need replacement
  • Document issue and contact IT support for battery capacity testing
PROBLEM

Intermittent Power Loss

Symptoms

  • Equipment reboots randomly
  • Network connectivity drops and restores
  • Cerbo GX shows voltage fluctuations

Likely Causes

  • Loose cable connections (vibration from wind)
  • Corroded terminals creating high resistance
  • Failing charge controller or power distribution component

Solutions

  • Systematically check and tighten all power connections
  • Clean and treat all terminals with dielectric grease
  • Secure cable runs to prevent movement and vibration
  • Monitor system for 24 hours after repairs to confirm resolution
  • If problem persists, contact IT support for component testing
When to Call for Support

Contact NMSU IT support immediately if you encounter:


Smoke, burning smell, or unusual heat from equipment

Battery swelling, leaking, or physical damage

Repeated fuse failures after replacement

Charge controller displaying persistent error codes

Any situation you're uncertain how to safely resolve

⚠️ Safety First: If equipment appears damaged or unsafe, power down the system and wait for professional assistance.