Chapter 2

Introduction

By the time installation begins, every major decision has already been made. The roof has been inspected. The equipment has been delivered. The panel layout has been finalised. Now the focus shifts from planning to construction.

Although a completed solar array appears relatively simple from the ground, a considerable amount of engineering lies beneath each panel. Mounting systems must support the weight of the array for decades while resisting strong winds, heavy rain and continual expansion and contraction as temperatures change throughout the year.Every bracket, rail and cable must be installed accurately. 

Small mistakes may not be immediately visible, but they can affect the safety, durability and long-term performance of the entire system. The goal is not simply to install solar panels. It is to create a secure, weatherproof structure capable of generating electricity reliably for decades.

Securing the Mounting System

The first stage of installation is attaching the mounting system to the roof. Rather than fixing solar panels directly onto roof tiles or metal sheets, installers first attach specially designed mounting brackets to the building's structural framework beneath the roof covering.

Depending on the roof construction, these brackets may be fixed into timber rafters, steel framing or other structural members capable of supporting the additional load. Each fixing point is positioned according to the engineering design so that the weight of the solar array is distributed safely across the roof.

The exact spacing of the brackets depends on several factors, including the type of roof, the size of the solar panels, expected wind loads and the manufacturer's installation requirements. Although only a small number of brackets may be visible once installation is complete, they form the structural foundation of the entire solar array.

Maintaining a Weatherproof Roof

Whenever the roof covering is penetrated, preventing water ingress becomes a critical priority. Professional mounting systems are specifically designed to maintain the roof's weather resistance while securely supporting the solar array.

Depending on the roofing material, installers may use purpose-built flashing systems, sealing components or waterproof mounting hardware to protect each penetration. Roof tiles are carefully repositioned where necessary, while metal roofs often use specialised fixing systems that minimise unnecessary penetrations altogether.

Every fixing point is inspected before installation continues. A properly installed solar system should generate electricity, not create roof leaks.

Installing the Mounting Rails

Once the brackets are installed, aluminium mounting rails are secured across the roof. These rails provide the framework that supports every solar panel. Careful alignment is essential. Rails must remain straight, level and parallel to ensure the panels fit correctly and that loads are shared evenly across the mounting system.

Installers also maintain the correct spacing between rails to match the dimensions specified by the panel manufacturer.

Although the rails disappear beneath the completed array, they perform much of the structural work throughout the lifetime of the installation.

Installing the Solar Panels

With the mounting system complete, the solar panels can be lifted onto the roof. Panels are positioned according to the approved layout and carefully placed onto the mounting rails. 

Each module is secured using specially designed clamps that grip the panel frame without damaging the glass or placing unnecessary stress on the module. Manufacturers specify exactly where these clamps should be positioned to ensure the panel can safely withstand wind, snow and other environmental loads. 

Installers also maintain small gaps between neighbouring panels. These gaps allow for manufacturing tolerances, thermal expansion and drainage while giving the finished array a neat, consistent appearance. As each panel is installed, its position is checked against the overall layout before the next module is added.

Allowing the Panels to Breathe

Although solar panels are designed to operate outdoors, they perform best when they remain as cool as possible. For this reason, panels are not installed directly against the roof surface. Instead, the mounting system creates a small air gap beneath the array.

As sunlight heats the panels, warm air naturally rises through this gap and is replaced by cooler air from below.

This continuous airflow helps remove heat from the modules, reducing operating temperatures and improving electrical performance.

The gap also allows rainwater, leaves and debris to pass beneath the array rather than becoming trapped against the roof. Good mounting design therefore improves both performance and durability.

Connecting the Panels

As each panel is installed, it is connected to the next using factory-fitted electrical connectors. Following the electrical design completed in Part 5, the panels are connected into strings that will later be connected to the inverter.

The polarity of every connection is carefully checked during installation to prevent wiring errors. Cables are routed neatly beneath the panels using dedicated clips and supports that prevent unnecessary movement. This protects the cables from abrasion, ultraviolet exposure and contact with the roof surface.

Neat cable management is more than good housekeeping. It reduces the likelihood of future faults while making inspection and maintenance significantly easier.

Completing the Installation

Once every panel has been installed, the entire array is inspected before electrical commissioning begins. Installers verify that all mounting brackets, rails and clamps have been tightened correctly and that every panel is securely fixed. They confirm that cable routes remain protected, connectors are fully engaged and no wiring is under unnecessary tension. The alignment of the completed array is also checked to ensure the installation matches the original design.

These final visual inspections may appear simple, but they play an important role in identifying small issues before the system is energised. Professional workmanship is measured not only by how quickly a system is installed, but by how carefully every detail has been completed.

Looking Ahead

The rooftop array is now complete. The panels are securely mounted, protected from the weather and connected into their electrical strings. However, the solar panels alone cannot power a home.

The electricity they produce must still be converted, protected and connected safely to the building's electrical system.

In the next chapter, we'll move from the roof into the heart of the installation as we examine how the inverter, switchboard, batteries and other electrical equipment transform the completed array into a fully functioning solar power system.