Solar Road Studs Troubleshooting: Fix Common Faults (2025 Guide)

In the modern transportation system, solar road studs, as the "invisible guardians" of road safety, have long become indispensable facilities in low-visibility scenarios such as at night and in rainy and foggy conditions. These small yet durable devices are usually precisely installed at the edge of the road, along the center line, and on dangerous sections such as curves, steep slopes, and intersections. They are like "fireflies" on the road, clearly outlining the road profile through LED light sources and helping drivers quickly determine lane boundaries. According to statistics, it can effectively reduce the incidence of night traffic accidents by more than 30%.
 

However, when exposed to outdoor environments for a long time, solar road studs are bound to encounter various maintenance pain points: insufficient charging due to continuous rainy days, reduced brightness caused by dirt on the panel, internal water ingress due to aging of the seal, and damage to the shell caused by vehicle impact, etc. These problems not only cause the equipment to fail but also may pose road safety hazards.
 

As a brand dedicated to road safety facilities, NOKIN is well aware of the importance of efficient maintenance. Next, we will bring you a practical guide for troubleshooting and repairing solar road studs that can be directly applied to the ground. From visual inspection to electrical testing, from common fault solutions to preventive measures, we will guide you step by step to quickly locate problems, reduce maintenance costs, and ensure that each solar road stud always remains in the best working condition, continuously safeguarding road safety.
 

Process for Troubleshooting Solar Road Studs

Front-line maintenance personnel can troubleshoot in the following priority order. In areas with continuous rainy and foggy weather, priority should be given to checking charging and battery capacity issues to ensure efficient fault location.
 

Fault Classification and Troubleshooting of Solar Road Studs

Solar Road Studs Do Not Light Up or Have Very Low Brightness at Night

Performance:

solar road studs are completely dark at night or their brightness is significantly lower than the normal level. They can only work for a short period of time and cannot provide effective road guidance for drivers.
 

Possible causes:

The solar panels are blocked by leaves, sand and mud, or covered with oil stains on the surface, resulting in a decrease in charging efficiency.

The battery is discharged (not fully charged due to continuous rainy days) or aged (used for more than 2-3 years).

Open circuit connection, terminal corrosion, or reverse connection of positive and negative poles;

The light sensor failed (misjudged daytime and refused to activate the LED);

Controller firmware error or hardware failure.
 

Troubleshooting steps:

When there is sufficient sunlight during the day, carefully observe the surface of the solar panels of the solar road studs to check if there are any obvious obstructions or dirt accumulation. If so, clean them in time.

Use a multimeter, set it to the voltage measurement range, measure the open-circuit voltage of the solar panel when there is no load and the working voltage after connecting to a load, and compare them with the standard values in the product specification manual.

Also, use a multimeter to measure the voltage of the battery when it is static (not connected to a load) and the voltage after connecting to a load to determine the battery's capacity and performance.

Along the circuit line, inspect each connection point to ensure that the connections are firm without any signs of loosening or corrosion, and at the same time confirm that the polarity of the connections is correct.
 

Solution:

For contaminated solar panels, gently wipe them with a soft damp cloth to remove surface dirt.

If the solar panels are severely damaged and cannot be repaired, new solar panels need to be replaced.

If the battery is discharged, perform a charging operation. If the battery is damaged, replace it with a battery of the same model as the original one.

Repair the disconnected wiring part, reconnect it and ensure the connection is firm. For cases where the polarity is reversed, correct the polarity of the wiring.

For the problem of light sensor failure, replace the new light sensor.

If the controller malfunctions, try resetting it and restoring the default Settings. If the problem remains unsolved, replace the controller.
 

Preventive measures:

Establish a regular cleaning system for solar road studs, such as at least once a month, to ensure that the surface of the solar panels remains clean and unobstructed at all times.

When choosing solar road studs, select highly efficient solar panels and batteries with sufficient capacity to meet the charging and power usage requirements in different environments.

When installing solar road studs, professional measuring tools are used to optimize the installation Angle, enabling the solar panels to receive the maximum amount of sunlight.
 

Water Has Entered the Solar Road Studs/the Interior is Damp

Performance:

After opening the shell of the solar road stud, it can be seen that there is a fogging phenomenon inside.

Rust marks have appeared on the wiring part and the color has darkened.

When the solar road studs experience a short circuit, they cannot function properly, or their working condition is unstable, with intermittent lighting up or going out.
 

Possible causes:

The sealant has aged (used for more than 3 years), or the sealing ring has deformed;

The shell of the solar road stud was cracked due to the impact of a vehicle, or the screws were not tightened properly during installation, resulting in a gap.

The drainage/ventilation holes at the bottom of the solar road studs are blocked by silt and sand, and the condensate water inside cannot be discharged.
 

Troubleshooting steps:

Visual inspection: Check if there are any water seepage marks at the seams of the shell and whether the drainage holes at the bottom are blocked (they can be cleared with thin iron wire).

Internal inspection: Wear waterproof gloves to open the casing, observe whether the circuits and batteries are rusted, and take photos to record the location of the fault (for convenient after-sales communication).

Drying test: Place a desiccant (such as a silica gel bag) inside or dry it at a low temperature (temperature < 40℃ to avoid damaging the battery). After standing for 2 hours, observe whether there is still fogging.
 

Solution:

For cases where the sealing ring is aged or damaged, replace it with a brand new one.

If the casing is cracked, replace it with a new one.

For components that are severely rusted, such as circuit boards and wires, replace them.

After the repair is completed, conduct a water immersion test according to the IP rating standard or a water sprinkling test to simulate a rainy day environment and check the waterproof performance of the road studs.
 

Preventive measures:

When purchasing, give priority to solar road studs with a protection level of IP68 or above, and confirm that the manufacturer provides a waterproof test report.

When installing, tighten the screws as per the instructions. Additional weather-resistant sealant (such as silicone sealant) can be applied to the joints.

Establish a regular inspection system to check the sealing condition of the road studs at regular intervals (such as every quarter), and promptly identify and solve any problems.
 

The LED Flashing/Flashing Mode of the Solar Road Stud is Abnormal

Performance:

The flashing state of the LED light is unstable, sometimes fast and sometimes slow.

The flickering frequency is inconsistent with the normal setting, abnormally high or low.

Or the LED light remains constantly on and does not operate in the set flashing mode.
 

Possible causes:

The internal parameter Settings of the controller are incorrect, or the firmware malfunctions, resulting in the inability to correctly control the flashing mode of the LED.

The light sensor is covered by dust, water vapor, etc., which affects its perception of light, or the sensor itself malfunctions.

The power supply system is unstable, with voltage fluctuations, or the battery is aged and unable to provide a stable voltage.
 

Troubleshooting steps:

Check the setting options of the controller to confirm whether parameters such as the flashing frequency and on/off time are correct, and at the same time, check whether the wiring of the controller is firm.

Use an oscilloscope or multimeter to measure the voltage waveform of the power supply line and observe whether there is any voltage fluctuation.

Check whether the surface of the light sensor is clean and free of any dirt film covering it.
 

Solution:

For the case where the controller parameters are incorrect, reset the correct parameters.

If the firmware fails, try updating the controller's firmware or replacing it with a new one.

Clean the surface of the light sensor. If the sensor is damaged, replace it with a new one.

If it is a problem of battery aging, replace it with a new one.
 

Cracks in the Solar Road Stud Panel, Damaged Shell or Loose Fasteners

Performance:

Obvious cracks have appeared on the panel of the solar road studs, affecting the normal operation of the solar panels.

A damaged shell may cause internal components to be exposed and be affected by the external environment.

The fasteners are loose, and the road studs are prone to shift when impacted by vehicles, and even the upper and lower parts may separate.
 

Possible causes:

The material quality of the road studs themselves is relatively low. During long-term use, they cannot withstand the external forces such as the rolling and impact of vehicles.

During the installation process, it was not carried out in accordance with the correct methods and requirements, such as the fixing bolts not being tightened properly or the adhesive being used improperly, etc.

On some heavy-load sections, the load of vehicles exceeds the designed load-bearing capacity and compressive strength grade of the road studs.
 

Troubleshooting steps:

Check whether the fixing bolts are tightened and whether the adhesive is firm. If there is any loosening or falling off, make a record.

Check the product specification sheet to confirm whether the load-bearing and compressive strength grades of the road studs meet the requirements of the installation section.

Take photos of the damage on site and record the location, extent and other information of the damage.
 

Solution:

For damaged panels, casings and loose fasteners, replace them with new components in a timely manner.

When replacing the fasteners, use the adhesive or bolts specified by the manufacturer and tighten them according to the prescribed torque.

On high-load sections, load-bearing road studs should be selected based on actual conditions to enhance their compressive resistance.
 

The Battery Life of Solar Road Studs is Short/the Working Time at Night is Shortened

Performance:

The newly replaced battery shows a significant decline in endurance after a short period of use.

The discharge current of the battery is abnormal and does not match the normal standard value.
 

Possible causes:

After a long period of charge and discharge cycles, the battery shows signs of aging and its performance declines.

Non-original batteries were used, and their quality and performance cannot be guaranteed, with poor compatibility with road studs.

Frequent deep discharge, exceeding the normal discharge range of the battery, accelerates battery wear and tear.

In the low-temperature environment of winter, the performance of batteries will be affected and their discharge capacity will decline.
 

Troubleshooting steps:

Use a multimeter to measure the static voltage of the battery to determine its state of charge.

Conduct battery capacity tests, record the battery's discharge curve through professional discharge testing equipment, and assess the actual capacity of the battery.

Check the charging circuit and measure whether the charging current is normal and meets the charging requirements of the battery.
 

Solution:

Replace it with a rechargeable battery of the same model as the original one or the model recommended by the manufacturer, such as giving priority to high-temperature resistant and long-life battery types like LiFePO4.

In the circuit design of the road studs, an over-discharge protection circuit is added, and a reasonable discharge depth protection threshold is set to prevent the battery from over-discharging.
 

Preventive measures:

When purchasing solar road studs, choose reliable battery products to ensure the quality and performance of the batteries.

Install an over-discharge protection circuit on the road studs to monitor the battery's discharge status in real time. When the battery power reaches the protection threshold, the discharge circuit will be automatically cut off.

In cold regions, based on local climatic conditions, select battery types with good low-temperature performance, or equip road studs with insulation devices to reduce the impact of low temperatures on battery performance.
 

Solar Road Studs Maintenance Frequency and Records

Suggested Maintenance Cycle

Maintenance Record (Example Table)

FAQ

Q1: What should I do if the solar road studs don't light up on rainy days?

A1: First, check if the surface of the solar panel is covered with rainwater or sand (clean it in time), and then use a multimeter to measure the battery voltage (for a 12V system, it needs to be greater than 11.5V). If the voltage is low, it might be due to insufficient charging after continuous rainy days. On sunny days, charge for 12 hours and then test again. If it still doesn't light up after cleaning and charging, open the casing to check if water has entered (internal rust or fogging), and repair according to the steps mentioned in the article.
 

Q2: Is it necessary to cut off the power when replacing the battery of a solar road stud?

A2: Yes. First, disconnect the battery from the controller (disconnect the negative terminal first, then the positive terminal) to avoid short circuit and electric shock. When replacing the new battery, make sure that the positive and negative terminals are consistent with the original wiring (red positive and black negative). After connection, power on for testing again. Wear insulating gloves throughout the operation to prevent battery short circuits (short circuits may cause explosions).
 

Q3: How to ensure sealing and prevent water from entering when installing solar road studs?

A3: ① Select products with IP68 protection grade and confirm that there are complete sealing rings at the joints of the casing. ② When installing, tighten the screws as per the instructions (apply even force to avoid deformation of the sealing ring). ③ Apply a 1-2mm thick layer of weather-resistant silicone sealant at the gap where the shell contacts the road surface. Within 24 hours after installation, conduct a water spray test (use a high-pressure water gun to spray the joints) to confirm there is no seepage.