What tools do I need for solar street light troubleshooting on site?

Essential toolkit: digital multimeter (measure voltage and current), insulated screwdrivers, non-contact voltage tester (safety), mobile phone torch and camera, black cloth (for covering panel to simulate night), spare fuse set for the controller model, and the controller user manual (photograph it during installation).

My solar light is under warranty but the company is not responding - what do I do?

Document the problem with photos and videos. Send a written complaint by email (create a paper trail). If no response in 14 days, send a legal notice through your advocate. For government projects: report to the project implementing authority (gram panchayat, MEDA, ZP) who has contractual leverage over the supplier. Xera Tech's warranty service is handled directly by the Nashik service team - response within 5 working days for Maharashtra projects.

Is it safe to open a solar street light controller box myself?

At 12V or 24V DC (solar system voltage): yes, it is electrically safe - these voltages are below the lethal threshold. However, short-circuiting battery terminals can cause fire or explosion in damaged batteries. Always disconnect the battery negative terminal before working inside the controller box. For grid-connected components, engage a licensed electrician.

Complete Solar Street Light Troubleshooting Guide - All Problems & Fixes

Problem 1 - Light Does Not Turn On at Night

Check in order: 1) Battery voltage (measure at controller terminals with multimeter): below 11.5V (12V system) = battery over-discharged, wait 2–3 sunny days. If voltage does not recover, battery is damaged. 2) Photocell/sensor: cover it with cloth - if light turns on, sensor is faulty or shaded. 3) Controller LED status indicators: green flash = normal, red = fault. Consult controller manual for fault codes. 4) LED driver connection: check for loose terminals at LED input. 5) Fuse: some controllers have an inline fuse on the load output - check and replace if blown. 6) Controller settings: verify controller is not in 'manual off' mode (button accidentally pressed).

Problem 2 - Light is Dimmer Than Before

Gradual dimming over months: panel soiling (most likely - clean panel first). Battery aging - capacity has dropped below 70%, battery needs replacement. LED chip degradation - normal after 30,000+ hours (7+ years at 12h/day). Controller set to permanent dim mode - verify dimming schedule settings. Sudden dimming onset: battery partially discharged (recent cloudy period) - wait for sunny weather recharge. Controller protection triggered (low battery dim mode) - battery recovering from over-discharge. Verify by measuring panel output voltage at solar noon and battery charge voltage.

Problem 3 - Battery Not Charging

Panel voltage at solar noon should be 17–21V (for 12V system). If below 15V: panel may be shaded, dirty, or damaged. Check: clean panel, verify no new shade obstruction, measure panel open-circuit voltage with multimeter (should be 21–22V). If panel voltage is OK but battery voltage does not rise during the day: controller may be faulty (replace controller) or battery has internal failure (replace battery). Check controller-to-battery wiring - a corroded positive terminal can prevent charging even with good panel output.

Problem 4 - Light Turns On During the Day

The photocell is seeing 'dark' even in daylight. Causes: photocell sensor window is dirty - clean the small lens on the controller or fixture body. Photocell is shaded by a newly positioned mounting bracket, bird nest, or leaves. Photocell has failed (resistance stuck high) - replace controller or photocell module. Controller in 'always on' test mode - check DIP switches or app settings. Wire to photocell is broken - if photocell is wired as normally-closed, a broken wire simulates darkness.

Problem 5 - Light Works Intermittently

Works some nights, not others: marginal battery - just barely sufficient for full-night operation. Cloudy day = light works half night; sunny day = works full night. Battery replacement imminent. Check battery voltage at dusk (should be 13.0–13.2V for LiFePO4 after a full sunny day charge). Works initially then dims and cuts off: battery depletes mid-night - either battery aging or excessive load. Verify LED current draw matches controller settings. Works in winter, not in monsoon: panel undersized for reduced monsoon irradiance - may need panel upgrade or battery capacity increase.