Proven Results
Production Recovery
2-8%
Typical range based on site degradation profile. Higher recovery (up to 12%) seen in severely degraded sites with >5% anomaly coverage.
Anomaly Detection
94%
F1 score across thermal defect categories. Validated on 25,000+ module images across 40+ sites.
Review Time Reduction
↓ 70%
AI pre-screens thermal imagery. Inspectors focus only on flagged findings vs. reviewing all images.
Time to ROI
< 6 mo
Typical payback period from remediation of high-priority anomalies identified in first inspection cycle.
Standards Compliance
HelioLytix thermal analysis meets IEC TS 62446-3:2017 requirements for outdoor infrared thermography of photovoltaic systems.
- Inspection data captured under validated environmental conditions (≥600 W/m² irradiance, documented wind speed and cloud cover)
- Radiometric thermal data with calibrated ΔT measurements and temperature normalization
- Report outputs compatible with warranty claim documentation and insurance submissions
- CoA-based severity classification (Minor/Serious/Critical) per IEC guidelines
IEC 62446-3 compliance enables use of HelioLytix outputs for module warranty claims, insurance documentation, investor due diligence, and EPC commissioning verification.
Defect Detection Categories
HelioLytix detects and classifies thermal anomalies across all levels of the PV system, from individual cells to array-wide patterns.
RGB/Thermal split view with hotspot detection and production loss estimation
Array-level monitoring with string outage detection and anomaly summary
Cell-Level Defects
| Defect | Thermal Signature | ΔT Range | Severity | Recommended Action |
|---|---|---|---|---|
| Cell Hotspots | Localized overheating in individual cells | 10-40°C+ | Serious | Schedule replacement within maintenance cycle |
| Cracked Cells | Irregular thermal patterns, hot edges along crack lines | 5-20°C | Minor | Monitor progression, plan replacement |
| Interconnect Degradation | Busbar or ribbon hotspots, linear heating patterns | 15-35°C | Serious | Priority remediation within 30 days |
Module-Level Defects
| Defect | Thermal Signature | ΔT Range | Severity | Recommended Action |
|---|---|---|---|---|
| Bypass Diode Failure | 1/3 or 2/3 of module heated uniformly | 10-25°C | Serious | Replace diode or module within 30 days |
| Bypassed Substring | Uniform warming across 1/3 module section | 5-15°C | Minor | Monitor, plan remediation |
| Junction Box Hotspot | Localized heating at J-box location | 20-50°C+ | Critical | Immediate inspection within 24-48 hours |
| Delamination | Irregular thermal patterns, trapped air pockets | 5-15°C | Minor | Document for warranty, monitor progression |
String-Level Defects
| Defect | Thermal Signature | ΔT Range | Severity | Recommended Action |
|---|---|---|---|---|
| String Outage (Open Circuit) | Entire string appears cold relative to neighbors | -5 to -15°C | Critical | Immediate repair — full kW loss |
| Combiner Box Issues | Multiple strings showing similar anomalies | Varies | Serious | Inspect combiner box connections |
Array-Level Patterns
| Defect | Thermal Signature | ΔT Range | Severity | Recommended Action |
|---|---|---|---|---|
| PID (Potential Induced Degradation) | Edge patterns across multiple modules, systematic degradation | 3-10°C | Serious | System-level remediation, warranty documentation |
| Soiling Patterns | Cooler zones where soiling blocks irradiance | -3 to -8°C | Minor | Schedule cleaning, assess cleaning frequency |
| Shading Analysis | Predictable cold patterns from nearby objects | -5 to -15°C | Minor | Document for production modeling, vegetation management |
ΔT Classification System
Per IEC 62446-3 thermal inspection guidelines
| Severity | Temperature Delta (ΔT) | Action | Timeframe |
|---|---|---|---|
Minor | <10°C | Monitor | Next scheduled inspection |
Moderate | 10-20°C | Plan repair | Within maintenance cycle |
Serious | 20-40°C | Priority fix | Within 30 days |
Critical | >40°C | Immediate | Within 24-48 hours |
All ΔT measurements normalized to 1000 W/m² irradiance per IEC 62446-3 for cross-inspection comparability. Actual thresholds may be adjusted based on site-specific conditions and module specifications.
Detection Performance
Validated on 50+ utility-scale and C&I sites across 25,000+ module images
| Defect Type | Precision | Recall | F1 Score |
|---|---|---|---|
| Cell Hotspot | 96% | 94% | 95% |
| Bypass Diode Failure | 93% | 91% | 92% |
| String Outage | 98% | 97% | 97.5% |
| PID Pattern | 88% | 85% | 86.5% |
| Junction Box Hotspot | 91% | 89% | 90% |
| Cracked Cell | 89% | 86% | 87.5% |
| Soiling Pattern | 94% | 92% | 93% |
False Positive Rate: <3%
Reduces unnecessary truck rolls and field verification costs
Standard Test Conditions
Validation Method
Ground truth comparison with IEC 62446-3 certified thermographer manual inspection. Each detection cross-referenced with I-V curve measurements where available.
Production Data Integration
HelioLytix connects with your existing monitoring infrastructure to correlate thermal findings with actual production data, enabling precise revenue impact calculations.
Supported Platforms
Data Synchronization
- Real-time production data correlation with thermal anomalies
- Historical irradiance retrieval for IEC 62446-3 compliance validation
- Inverter-level and string-level performance mapping
- Automated anomaly-to-production-loss impact calculation
- Weather data overlay for normalized performance analysis
- Bi-directional sync for work order status updates
Integration Methods
REST API
OAuth 2.0 authentication with token refresh, rate limiting, and retry logic
Webhooks
Real-time alerts for production anomalies and maintenance status changes
Bulk Import
CSV/JSON/Excel file upload for historical data and site configuration
OPC UA
Direct SCADA connectivity for industrial-grade monitoring systems
Work Order Integration
HelioLytix generates actionable work orders directly in your O&M system, with thermal evidence attached and priority ranking based on production impact.
Supported Platforms
Export Formats
Work Order Contents
- GPS coordinates with click-to-navigate for field technicians
- Thermal image with annotated defect location and boundary
- Defect type classification and severity level
- Estimated daily/annual production loss in kWh and revenue
- Recommended remediation action with labor/parts estimate
- Priority ranking based on production impact and safety risk
- Historical thermal trend (if repeat inspection data available)
- IEC 62446-3 compliant documentation package
Supported Thermal Cameras
HelioLytix supports radiometric thermal imagery from leading drone and camera manufacturers, including NDAA-compliant options for U.S. government and utility projects.
DJI
- Mavic 3T / 3TD (Thermal)
- Matrice 30T
- Matrice 300 RTK + Zenmuse H20T
- Matrice 350 RTK + Zenmuse H20T
- Zenmuse XT2
- Zenmuse H20N (night thermal)
FLIR Systems
- FLIR Vue Pro R (radiometric)
- FLIR Duo Pro R
- FLIR Vue TZ20
Workswell
- Wiris Pro (radiometric)
- Wiris Enterprise
- Wiris Security
Autel (NDAA-Compliant)NDAA
- EVO II Dual 640T
- EVO II Dual 640T V3
- EVO Max 4T
Teledyne FLIR (NDAA-Compliant)NDAA
- SIRAS
- ION M640
Minimum Camera Requirements
IEC 62446-3 compliant (5×5 pixels per cell minimum)
Per-pixel temperature data for accurate ΔT measurement
Recommended for detecting early-stage thermal anomalies
Covers typical PV operating conditions
For continuous scanning during drone flyover
Optimal for 30-50m AGL inspection altitude
Built for Solar Professionals
HelioLytix is designed for teams who need reliable, scalable thermal analysis—from single-site inspections to portfolio-wide deployments.
Utility-Scale O&M
Portfolio-wide thermal analysis with IEC 62446-3 compliance, SCADA integration, and enterprise reporting.
- Multi-site portfolio dashboards
- IEC 62446-3 compliant documentation
- SCADA/monitoring integration (AlsoEnergy, PowerTrack)
- Enterprise SSO and role-based access
C&I Asset Managers
Fast, mobile-friendly inspection with automated work orders and production impact quantification.
- Mobile-first field interface
- Automated CMMS work orders
- Production loss in $/kWh
- Multi-tenant site management
Drone Service Providers
White-label reporting with multi-client management and brandable deliverables.
- White-label PDF reports
- Client portal with branded access
- Bulk processing for high-volume ops
- Per-client billing and analytics
EPC Contractors
Commissioning baseline documentation with warranty-ready thermal records.
- Pre-handoff thermal baseline
- IEC 62446-3 commissioning reports
- Defect punch list generation
- Warranty documentation package
Why HelioLytix?
Unlike generic thermal analysis tools, HelioLytix is purpose-built for solar O&M with direct production data integration—turning thermal imagery into actionable, ROI-prioritized maintenance decisions.
Edge-First Analysis
Field results in real-time
No waiting for cloud processing. Technicians see anomaly flags during the drone flight and can remediate same-day, reducing truck rolls and site revisits.
Production Impact Quantification
Every anomaly includes $/year loss
Correlate thermal severity with actual production data to calculate revenue impact. Prioritize maintenance by ROI, not just temperature delta.
IEC 62446-3 Compliance
Warranty-ready documentation
Reports meet IEC 62446-3:2017 requirements for warranty claims, insurance submissions, and investor due diligence. Includes all required environmental validation.
Native Monitoring Integration
Direct SCADA connection
Pull real-time production data from AlsoEnergy, SolarEdge, Enphase, and other platforms to correlate thermal anomalies with actual performance degradation.
Outcomes
What it does
- Hot-spot and underperforming panel detection from thermal imagery
- Panel string mapping with production impact estimates
- Maintenance work orders prioritized by revenue loss
- GIS overlay of panel health by string and inverter
- Integration with monitoring systems (SolarEdge, Huawei, etc.)
How it works
Thermal imagery (drone/fixed) → anomaly detection → production loss model → priority queue → maintenance work orders → output tracking
What you get
- Thermal anomaly detection (86-97% F1 score by defect type, <3% false positive rate)
- GIS overlay of panel health by string and inverter
- Production loss estimates and maintenance prioritization
- Integration with monitoring systems (SolarEdge, Huawei, etc.)
- Automated work order generation with thermal evidence
Deployments & integrations
- Edge (field tablets)
- Batch processing for periodic thermal scans
- GIS + monitoring system integration
Security & governance
- TLS 1.3 for all data in transit, AES-256 at rest
- Role-based access (O&M tech, asset manager, exec dashboard)
- Audit logs for all maintenance actions and evidence access
- On-prem deployment option for sensitive sites
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