Introduction

Your solar system’s wiring is like the veins of the entire installation.
One loose connection, thin cable, or burnt wire can cause:

❌ inverter tripping
❌ low voltage
❌ overheating
❌ weak charging
❌ burning smell
❌ battery damage
❌ complete system shutdown

Most solar problems in Nigeria come from poor wiring by untrained installers.

In this guide, Solarzone Nigeria reveals the major wiring problems, the symptoms to watch out for, and the exact solutions.

⭐ 1️⃣ Undersized Cables (Thin Wires)

Using small wires causes:

• heat buildup

• voltage drop

• inverter strain

• burning smell

• fire risk

❌ Signs:

• warm or hot cables

• inverter struggling under load

• low charging from panels

• dim lights on solar

✔ Fix:

Use correct cable sizes:

• 10mm – 25mm for battery & inverter

• 6mm – 10mm for solar panels

• 4mm – 6mm for AC output

Solarzone corrects all cable sizing issues.

⭐ 2️⃣ Loose Terminals and Connections

Loose connections cause:

• crackling sound

• voltage drop

• sparks

• overheating

❌ Signs:

• inverter fan runs constantly

• wires feel hot

• inverter shuts down randomly

• burning smell

✔ Fix:

• tighten all terminals

• clean corroded ends

• replace damaged connectors

Loose terminals are the #1 cause of burnt inverters.

⭐ 3️⃣ Wrong Wiring Configuration (Series/Parallel Errors)

Incorrect solar panel wiring results in:
❌ wrong voltage
❌ weak current
❌ MPPT errors
❌ poor daytime charging

✔ Fix:

• reconnect panels in proper series/parallel

• match panel voltage to MPPT requirement

• use same wattage panels

Solarzone rewires arrays for maximum performance.

⭐ 4️⃣ Bad or Burnt MC4 Connectors

MC4 connectors burn when:

• poorly crimped

• loose

• moisture enters

• high current flows

❌ Signs:

• low power from panels

• MPPT fluctuating

• burning/plastic smell

✔ Fix:

• replace burnt MC4s

• re-crimp using proper tools

• waterproof joints

⭐ 5️⃣ Wrong Polarity Connections

Reversing Positive (+) and Negative (-) will:
❌ damage controller
❌ trip inverter
❌ burn fuses
❌ stop charging

❌ Symptoms:

• no charging

• sparks on connection

• blown MPPT

• inverter alarm

✔ Fix:

Solarzone checks and corrects polarity safely.

⭐ 6️⃣ Mixed or Poorly Matched Solar Panels

Using different:

• wattage

• brands

• voltage

• cell type

causes imbalance in the system.

❌ Signs:

• poor charging

• MPPT running hot

• inverter instability

✔ Fix:

Use properly matched panels
OR
Rewire them into compatible groups.

⭐ 7️⃣ Corroded or Oxidized Wires

Corrosion reduces conductivity.

❌ Signs:

• weak charging

• MPPT not reading power

• inverter voltage drop

✔ Fix:

• replace corroded wires

• protect terminals

• use waterproof MC4s

⭐ 8️⃣ Breaker/Isolation Switch Problems

Wrong breakers cause:
❌ nuisance tripping
❌ overheating
❌ arcing
❌ inverter shutdown

✔ Fix:

Use correct:

• DC breakers

• AC breakers

• isolators

• surge protectors

Solarzone installs safety-compliant protection gear.

⭐ 9️⃣ Poor Battery Connection Wiring

Battery wiring must be:
✔ balanced
✔ thick
✔ tight
✔ corrosion-free

❌ Problems:

• wrong series/parallel connections

• uneven charge distribution

• low backup time

✔ Fix:

Solarzone configures battery banks correctly.

⭐ 🔟 Exposed Wires & Poor Conduit Routing

Exposed wires cause:

• shocks

• fire hazards

• cable damage

• weather damage

✔ Fix:

• use proper conduits

• secure wall cables

• protect roof cables

⭐ 11️⃣ Overloaded Wiring Circuits

If too many appliances feed one circuit:

• wires heat

• breakers trip

• inverter overloads

✔ Fix:

• split load properly

• use dedicated lines for AC/freezers

• upgrade cable capacity

⭐ When to Call Solarzone for Wiring Repair

Contact Solarzone if you notice:
✔ burning smell
✔ inverter tripping
✔ wires heating up
✔ weak charging
✔ low voltage
✔ MPPT errors
✔ crackling sounds
✔ inverter fan always on
✔ exposed wires
✔ flickering lights

We offer:
⭐ wiring diagnosis
⭐ full wiring correction
⭐ panel rewiring
⭐ battery bank configuration
⭐ MC4 replacement
⭐ inverter safety upgrade
⭐ load balancing

🏁 Final Thoughts

Wiring problems are silent killers of solar systems.

They cause:
✔ overheating
✔ power loss
✔ battery damage
✔ inverter burnout
✔ fire risk

But the good news?
Most wiring issues can be fixed quickly with proper inspection.

Let Solarzone Nigeria diagnose and fix your system wiring professionally.

💥 Call to Action

⚡ Need wiring correction or solar troubleshooting?
Contact Solarzone Nigeria today.

📞 Call/WhatsApp: 09091394722