DIY Guide: Solar Panel Installation Best Practices

By Frank Underdown, PhD

Welcome to the fourth installment of our DIY series on installing a home solar energy system! In the last article, we discussed wiring and connecting the components of your solar system. Now, we’ll shift our focus to installation best practices, covering how to mount your solar panels, optimize their tilt and orientation, and ensure long-term durability. By following these steps, you’ll maximize your system’s performance and lifespan.

Step 1: Select the Right Mounting Location

Choosing the right spot to install your solar panels is essential to ensure optimal energy production. Consider these factors:

• Sunlight Exposure: Choose a location that gets direct sunlight for most of the day (ideally, 5+ peak sun hours).
• Minimal Shading: Ensure there’s no shading from trees, buildings, or chimneys that could reduce output.
• Roof Strength: Confirm that your roof can support the additional weight of the panels.

Alternative Options: If your roof isn’t ideal, consider ground-mounted systems or solar canopies.

Step 2: Choose the Right Mounting System

The mounting system secures your panels in place and affects their orientation and angle. There are three common types:

1. Roof-Mounted: Flat Roofs: Use ballasted mounts or tilted racks. Pitched Roofs: Use flush mounts that follow the roof’s angle.
2. Ground-Mounted: Installed on a frame anchored to the ground, ideal for homes with limited roof space.
3. Solar Canopies: Dual-purpose structures that provide shade while generating electricity.

Tip: Choose corrosion-resistant materials such as aluminum or stainless steel to ensure long-lasting support.

Step 3: Optimize Panel Tilt and Orientation

Proper tilt and orientation are critical to maximizing energy production.

• Optimal Orientation (Northern Hemisphere): Panels should face south to capture the most sunlight.
• Tilt Angle:As a rule of thumb, set the tilt angle equal to your latitude (e.g., 30° if you live at 30° latitude). For off-grid systems requiring year-round efficiency, adjust the tilt seasonally:Summer: Latitude - 15° Winter: Latitude + 15°

Tip: For fixed installations, an angle close to your latitude will work well year-round. Adjustable mounts offer greater flexibility but can be more expensive.

Step 4: Secure the Mounting System

Proper installation of the mounting system ensures that panels stay in place even during extreme weather conditions.

Steps for Roof-Mounted Systems:

1. Locate Rafters: Use a stud finder to find roof rafters for secure attachment.
2. Install Flashing: Waterproof flashing protects against leaks at the mounting points.
3. Attach Mounting Brackets: Use lag bolts to secure brackets into the rafters.
4. Position and Secure Rails: Attach rails to the brackets, ensuring they are level and properly aligned.

Steps for Ground-Mounted Systems:

1. Excavate Holes: Dig holes for the foundation posts based on manufacturer instructions.
2. Install Posts: Secure the posts in concrete to ensure stability.
3. Attach Rails and Mounts: Follow the same steps as roof-mounted systems to attach the rails and mounts.

Tip: Regularly check for loose bolts and connections, especially after severe weather.

Step 5: Mount the Solar Panels

Once the mounting system is securely in place, it’s time to install the solar panels.

1. Position Panels: Lift the panels onto the rails or brackets, aligning them properly.
2. Secure Panels: Use the provided clamps or mounting hardware to fasten panels to the rails.
3. Check Alignment: Ensure panels are aligned and evenly spaced to avoid shading between rows.

Safety Tip: Work with a partner when handling panels to reduce the risk of damage or injury.

Step 6: Manage Wiring and Cables

Proper cable management prevents damage and improves aesthetics.

1. Secure Cables: Use zip ties or cable clips to attach cables to the mounting structure.
2. Avoid Sagging: Ensure cables are tight but not overstretched.
3. Protect Exposed Wires: Use conduit to shield wires from UV damage, weather, and rodents.

Tip: Label all cables for easier maintenance and troubleshooting.

Step 7: Grounding and Surge Protection

Grounding protects your system and home from electrical surges.

1. Ground Each Panel: Follow manufacturer instructions to connect grounding wires to each panel frame.
2. Install a Grounding Rod: Drive the grounding rod into the ground and connect it to the system’s grounding bus.
3. Surge Protection Devices: Install surge protectors at key points to safeguard sensitive components.

Step 8: Final Inspection and Testing

1. Double-Check Connections: Verify that all bolts, cables, and grounding wires are secure.
2. Check Tilt and Orientation: Ensure panels are at the proper angle and facing the correct direction.
3. Test Voltage and Current: Use a multimeter to measure output from the panels and confirm it matches the expected values.

Tip: Record baseline performance data to monitor long-term system efficiency.

Maintenance Tips for Longevity

• Clean Panels Regularly: Dust, dirt, and debris can reduce efficiency.
• Inspect for Damage: Check for cracks, corrosion, or loose connections every 6–12 months.
• Monitor Output: Use the system’s monitoring app to detect performance drops early.

Tools and Materials Needed

• Stud finder (for roof-mounted systems)
• Wrench and screwdriver set
• Power drill
• Lag bolts and flashing (for roofs)
• Zip ties and cable clips
• Grounding wire and rod

Supplier Recommendations for Mounting Systems

1. Roof and Ground-Mounted Solutions: IronRidge: ironridge.com Unirac: unirac.com
2. Cable Management and Grounding Supplies: Panduit: panduit.com Blue Sea Systems: bluesea.com

Next Steps

In the next article, we’ll cover system performance optimization and maintenance, including how to monitor efficiency, troubleshoot issues, and extend the lifespan of your solar energy system. Stay tuned!

Frank Underdown, PhD, specializes in solving complex engineering challenges, with expertise in renewable energy and sustainability solutions.