Solar Panel Installation

Installing solar panels is no longer a luxury choice or merely an environmental gesture. It has become an economic, technical, and strategic decision for anyone aiming to reduce energy costs and decrease reliance on the national power grid. With electricity prices rising steadily and energy crises becoming increasingly evident in many regions, solar panel installation is gaining serious attention across industries, agriculture, residential properties, and even government organizations.

But let’s not be mistaken—installing solar panels is not just about placing a few black sheets on a rooftop. This is a full-fledged technical project that demands detailed site analysis, understanding of photovoltaic systems, careful equipment selection, strict safety compliance, and precise electrical configuration. In fact, the final efficiency and performance of a solar system depend heavily on the accuracy and professionalism of the installation process.

This article aims to walk you through the solar panel installation process from A to Z, combining a straightforward style with real technical insight. Instead of repeating clichés, we’ll dive into real-world details—from physical mounting techniques and safety practices to common challenges and the engineering solutions that resolve them.

If you’re planning to design a solar system or just want to understand what makes a solar project successful, keep reading—this is exactly for you.

 

 

Physical Installation Steps of Solar Panels

The physical mounting of solar panels is one of the most critical phases of any solar system implementation. Mistakes at this stage—even with the best equipment—can result in significantly lower efficiency, higher maintenance costs, or even early system failure. Let’s go step-by-step through the proper installation process:

1. Site Assessment and Solar Radiation Analysis

Before anything is installed, the site must be thoroughly assessed—not just visually, but using data and technical analysis. Solar radiation levels throughout the year must be evaluated, shading obstacles (like trees, towers, or surrounding walls) identified, and the tilt and orientation of the roof or ground precisely measured.

Example: In a livestock farm project in Hamedan, although the rooftop was large, a tall water tank on the west side cast a shadow over part of the panels after 2 PM. Relocating the panels to the southern side and tilting them at 35° resolved the shading issue and increased energy output by 18%.

2. Design and Preparation of the Mounting Structure

The structure supporting the panels must be robust and tailored to the optimal angle and orientation. Typically made from galvanized steel or aluminum, the mount must withstand wind, earthquakes, snow, and ground settling.

Note: In windy regions, using heavy-duty frames and anti-vibration bolts is essential. In a project in Bandar Abbas, weak structures led to two panels being torn off in a storm. Re-engineering the frame with metal windbreakers solved the problem.

3. Mounting Panels with Mechanical Precision

Installing the panels involves mounting the modules on the structure, tightening bolts with correct torque, maintaining space between panels for airflow, and using certified clamps.

Common Mistake: Over-tightening bolts or using substandard clamps can crack panel glass or apply uneven pressure on cells, which decreases performance over time.

4. DC Cabling and Series/Parallel Connections

Panels are connected in series or parallel based on the electrical design. Proper solar-rated cables (UV-resistant), certified MC4 connectors, and correct current direction are crucial.

Example: In a residential project in Rasht, standard household wires were used instead of DC solar cables. Due to sun and rain exposure, the cables degraded within a year and caused a short circuit. Switching to dedicated solar cables resolved the issue permanently.

5. Inverter and DC Fuse Box Installation

The inverter is the brain of your solar system—converting DC power from the panels into AC for appliances. It should be installed in a cool, shaded, ventilated area close to the panels to minimize voltage drop.

Tip: In hot climates, placing the inverter in an air-conditioned room or shaded structure significantly extends its lifespan.

6. Grounding and Shock Protection System

Many mistakenly think solar systems don’t need grounding due to low voltage. However, proper grounding, fuses, surge protection devices (SPDs), and DC circuit breakers are essential in any professional system.

7. Final Testing and Commissioning

Once installed, the system must undergo functional and safety testing. Output voltage, current flow per string, and inverter setup for energy logging should be checked. Industrial projects often require a Commissioning Report with all key parameters. Using clamp meters and even thermal cameras (to detect hot spots) is recommended.

 

 

Solar Panel Installation – Safety Measures

Even with high-quality equipment, if safety is overlooked, the risks can be serious—from electric shock and technician falls to fire hazards and system failure. Unfortunately, safety is often ignored or only symbolically followed, even in semi-industrial projects. But neglecting safety during installation is like driving downhill with no brakes. Let’s review the most critical safety guidelines with real-world context:

1. Fully Disconnect Power Before Any Connection

A common mistake is assuming DC current is harmless. In reality, DC is far more dangerous than AC and harder to interrupt. If connectors are unplugged while current is flowing, dangerous electric arcs may form, potentially causing fire.

Example: In a residential project in Qazvin, a technician connected the inverter without disconnecting the DC circuit and suffered hand burns and nerve damage due to a short circuit. A simple DC breaker could’ve prevented the injury.

2. Use Personal Protective Equipment (PPE)

Helmets, anti-slip shoes, insulated gloves, protective goggles, and safety harnesses aren’t luxuries—they’re essential. Especially in rooftop or heavy-equipment projects.

Note: On a factory rooftop in Isfahan, a worker installing panels without a safety harness fell due to wind. After the accident, safety protocols were overhauled, and harnesses became mandatory for all rooftop work.

3. Grounding and Lightning Protection

Grounding (earthing) isn’t just for human safety—it also protects sensitive equipment like inverters and charge controllers. In lightning-prone areas, installing lightning rods or SPDs is highly recommended.

Example: A solar farm in Fars province had properly mounted panels, but no lightning protection. One storm destroyed several panels and the main inverter. After installing SPDs and professional grounding, the issue never repeated.

4. Prevent Short Circuits During Cabling

Minor errors during connector installation can cause shorts, damaging panels and risking fire. Use proper tools like MC4 wrenches and always test before final connection.

5. Maintain Safe Distance from Roof Edges

In rooftop installations, technicians should stay at least one meter away from edges, and the layout should minimize edge exposure. Scaffolding or safe ladders are essential for transporting equipment.

6. Train the Installation Team Thoroughly

Nothing replaces proper training. Even with the best tools, an untrained crew poses serious risks when handling DC electricity, working at height, or managing sensitive electronics.

 

 

Common Installation Mistakes and How to Avoid Them

Although solar panel installation may seem straightforward, overlooking even minor technical details can drastically reduce system performance, lifespan, or safety. Below are some of the most frequent technical/execution errors and the best engineering solutions:

1. Incorrect Panel Tilt Angle

Problem: Panels mounted at improper angles reduce direct sunlight exposure, cutting energy output.

Solution: Set the angle close to the site’s latitude (±10° depending on season). Use design software like PVsyst for precise calculations. For fixed mounts, choose the angle that maximizes annual output, not just seasonal.

2. Shading on Panel Surfaces

Problem: Even partial shade from an antenna, AC unit, or tree can drop performance of the entire string due to series wiring.

Solution: Conduct thorough shading analysis using shadow meters or simulation software. Use bypass diodes to minimize shading impact.

3. Poor or Loose DC Connections

Problem: Weak or improperly crimped connections can cause hot spots, efficiency loss, or fire.

Solution: Use original MC4 connectors, standard crimping tools, and verify all connections with pull tests and thermal imaging.

4. Improper Inverter Placement

Problem: Inverters installed outdoors without protection fail faster due to heat, dust, or vibration.

Solution: Place inverters in cool, ventilated rooms, raised at least 80 cm off the ground, in shaded areas below 45°C, and use protective boxes if outdoors.

5. Mismatched Inverter and Panel Capacity

Problem: Some systems match inverter capacity exactly to panel rating—or undersize it—which can cause overload or energy waste.

Solution: Oversize panels by 10–30% (e.g., 6500 W of panels + 5000 W inverter) for optimal early/late day performance. Modern inverters can handle it safely.

6. Incomplete Grounding or Surge Protection

Problem: Small systems often lack proper earthing or surge protection, making them vulnerable to electric discharge, voltage spikes, or static buildup.

Solution: Install an independent ground with resistance <5 ohms, use uncoated copper wires (≥16 mm²), and mount lightning rods at safe distances. Always test resistance before launch.

7. Improper Panel Cleaning

Problem: Dust buildup reduces output. Improper cleaning with hard water or rough cloths scratches the glass and blocks light.

Solution: Clean with deionized or distilled water, soft fiber brushes, and avoid cleaning during hot hours to prevent thermal shock. Establish a regular cleaning schedule (e.g., every 2 months).

 

 

Contacting Shamim Andisheh

To connect with Shamim Andisheh Company and receive expert consultation on solar panel installation, you can visit our headquarters and speak directly with our engineering team. Our specialists will assess your solar system requirements and offer personalized guidance across every project stage—from design to execution and maintenance. We’re committed to helping you execute your solar project with global standards—accurately, safely, and cost-effectively.

Contact Information:

• 📞 Phone: 021-44071011 (ext. 12)
• 📧 Email: shamim@shamimco.com
• 🌐 Website: www.shamimco.com
• 📱 Social Media & WhatsApp: +98-939-412-1002