At SunMade Power, we specialize in uncovering and addressing the hidden failures that quietly drain revenue, shorten asset life, and put grid compliance at risk.

Here are the top three issues we’re seeing in the field—and what we can do to fix them.

#1: Out-of-Balance LFP Batteries

The Issue: This is the #1 hidden killer of energy capacity. Over time, cell-level voltage drift—especially at high or low states of charge—limits full cycling of the system. Even relatively new sites can lose 10–25% of usable capacity.

Revenue Impact: Up to $250,000/year in lost energy revenue for a 10 MWh system.

SunMade Fix: We offer a free site performance audit to assess balancing issues. If rebalancing is needed, we implement a custom plan starting at $1,000/year per MWh—or $10,000/year for a 10 MWh system. That’s a 96% savings opportunity and a 25:1 return on investment—every $1 spent protects $25 in revenue.

#2: Aging Systems Need Repowering or Augmentation

The Issue:

As BESS assets age, cell degradation, inverter inefficiency, and HVAC decline all chip away at system output. Within just 3–5 years, many sites experience a noticeable drop from nameplate performance—often without realizing how far they’ve slipped until revenue takes a hit or compliance becomes a concern.

Revenue Risk:

Cumulative underperformance can exceed $300,000+ over just a few years, along with the risk of missed offtake targets or grid compliance penalties.

SunMade Fix:

We provide comprehensive site health assessments, including capacity testing, degradation modeling, and inverter performance analysis. From there, we recommend targeted augmentation or repowering strategies—including integration of new batteries or hybrid components—tailored to your operational and financial goals.

#3: Environmental Damage from Poor HVAC Design or Failure

The Issue:

HVAC issues are one of the most common (and overlooked) sources of BESS degradation. Inadequate temperature control, condensation buildup, or airflow design flaws can cause humidity-related damage, trigger thermal events, or degrade battery performance far faster than expected. These problems often emerge gradually but can lead to serious consequences if left unaddressed.

Revenue Risk:

Uncontrolled temperature swings or moisture intrusion can result in multi-million-dollar equipment failures, unexpected derate events, or accelerated asset degradation—especially in hot or humid environments.

SunMade Fix:

We inspect, test, and optimize BESS HVAC systems to ensure thermal protection meets OEM specs. Services include real-time HVAC monitoring, condensation control retrofits, and custom airflow engineering to prevent long-term damage and downtime.