Size Matters: Dimensional Challenges in Modern Solar Modules

The Changing Landscape of Solar Panel Dimensions

In the last five years or so, the solar panel manufacturing process has changed a great deal and become much more varied in terms of how panels are designed. The biggest impact of this is that the older dimensions are discontinued and no longer available, making replacement of older panels effectively impossible.

Replacing Older Panels: A Common Challenge

Multiple times a week, we get inquiries from customers about how to replace an older panel that has been damaged. Invariably, our response is “just claim it with your insurance,” since it is not possible to source panels in the old dimensions (which were 65” x 40” for standard residential solar). The only place a customer might find some of those earlier modules (i.e., anything before 2020) is online as a used or secondhand purchase.

Modern Panel Sizes: A Wide Range of Dimensions

To make things even more confusing going forward, the various half-cell production techniques now result in a profusion of dimensional variations. This can be seen in the examples below - all of these are currently available panels in the 390-410 watt range.

• Canadian Solar CS3N-395MS: 76.4 x 41.3 x 1.38
• Hanwha Q.PEAK DUO BLK ML G10+ 405: 74 x 41.1 x 1.26
• Hyundai HiS-S410YH(BK): 75.74 x 40.86 x 1.26
• JA Solar JAM54S31-405/MR: 67.8 x 44.65 x 1.18
• Jinko JKM390M-72HBL-V-D1: 79.06 x 39.45 x 1.57
• Meyer Burger MB-390-HJT120-BB-T2: 69.57 x 40.98 x 1.38
• REC Solar REC400AA: 71.7 x 40 x 1.2
• Trina TSM-410-NE09RC.05: 69.37 x 44.65 x 1.18

As you can see, none of these are even close to being the same.

Planning Ahead: Tips for New System Buyers

On a practical level, system owners and designers may want to consider buying a few extra panels as insurance for a new system since it’s very likely that an exact match won’t be available after a few years. Even with a valid warranty, a replacement module may not be in stock, which could pose an issue.

Inverter Compatibility: What You Need to Know

Fortunately, almost all modern inverters can survive the loss of a damaged panel or two. This mainly becomes an issue in older string inverter models, where damaged panels can reduce the string’s voltage below the minimum inverter requirement. However, this is not an issue at all in modern micro-inverter or optimizer systems, beyond the loss of the damaged panel itself.

Conclusion: Future-Proofing Your Solar Investment

As solar panel technology continues to evolve, it's essential for system owners and new buyers to be aware of the changes in panel dimensions and what they mean for long-term maintenance. With older sizes becoming obsolete, replacing damaged panels on legacy systems can be a challenge. To minimize potential issues down the road, consider purchasing extra panels at the time of installation or upgrading to a more adaptable inverter system.

By planning ahead, you can ensure that your solar investment remains productive and efficient, no matter what advancements come to the industry. If you have any questions about replacement panels or need guidance on selecting the right components for your setup, our team is always here to help.