PV installation:

PV Installation Process Description

The installation of photovoltaic (PV) modules involves a systematic sequence of activities that ensures the safe, efficient, and high-quality assembly of solar panels onto pre-constructed mounting structures, connecting them into functional electrical arrays.

  1. Pre-Installation Preparation
  • Material Inspection: Verify receipt of PV modules, mounting structures, fasteners, and accessories against delivery notes and specifications. Check for physical damage.
  • Layout Verification: Confirm string layout, tilt angles, and orientation (typically facing true south in the northern hemisphere).
  • Tool Preparation: Ensure availability of torque wrenches, hand tools, lifting devices, grounding test kits, PPE, and lifting equipment.
  1. Mounting Structure Installation

(Assumes pile-driven or concrete foundation is already complete)

  • Erect mounting structures as per approved shop drawings.
  • Verify structure alignment (verticality and level) using laser level and spirit level.
  • Secure all bolts and fasteners to specified torque values.
  • Perform visual inspection of structural components for corrosion or defects.
  1. PV Module Installation
  • Module Handling: Carefully lift and position modules to prevent glass breakage or micro-cracks. Avoid dragging across surfaces.
  • Fixing Modules:
    • Align modules as per the layout plan.
    • Fasten modules using certified clamps/brackets, maintaining specified gaps between modules (thermal expansion spacing).
    • Torque all module fasteners to manufacturer specifications (typically 8–12 Nm).
  • Grounding: Connect module frames to the structure’s grounding system using grounding lugs and bonding jumpers where required.
  1. Electrical Interconnections
  • String Connections:
    • Connect PV modules in series to form strings using MC4 or equivalent connectors.
    • Ensure correct polarity and voltage levels match design parameters.
  • Combiner Boxes:
    • Route string cables (DC) to combiner boxes mounted on the mounting structure or dedicated poles.
    • Use UV- and weather-resistant cable ties and conduits for cable management.
  • Earthing:
    • Connect module frames and structures to the earthing system using copper wires or earthing tapes.
    • Verify continuity and resistance of the grounding system (target <10 ohms or per spec).
  1. Testing and Commissioning
  • Pre-Commissioning Tests:
    • Perform Insulation Resistance Test (megger test) on string cables.
    • Verify open circuit voltage (Voc) and short circuit current (Isc) of each string.
    • Confirm polarity and check for any mismatch in connections.
  • Functionality Check:
    • Monitor system output after energizing (if connected to inverter/SCADA).
    • Ensure all connections are tight and safe, with no exposed live terminals.
  • Document all test results and hand over for QA/QC approval.
  1. Cleaning and Final Inspection
  • Clean modules with soft water and lint-free cloths (if dusty).
  • Conduct final visual inspection for defects, loose connections, and physical alignment.
  • Mark strings and array sections with permanent labels for future maintenance.
  1. Safety and Environmental Considerations
  • Workers must wear PPE: gloves, helmets, safety shoes, harnesses (for elevated work).
  • Implement lockout/tagout procedures during electrical work.
  • Ensure all work follows relevant standards (e.g., IEC, NEC, local electrical codes).