🛠️ Jeho Ashar Solar Energy – Installer’s Field Manual

Step-by-Step Guide to Installing Solar Panels

🔹 Step 1: Site Inspection and Planning

What to Check:

• Roof Direction: South-facing is ideal (in the Northern Hemisphere).
• Sunlight Availability: No shade from trees or buildings.
• Roof Space: Enough area for required panels.
• Tilt Angle: Preferably equals local latitude.
• Structural Strength: Roof must support panel weight.

Tools:

• Measuring tape
• Compass or smartphone app
• Sun-tracking app (e.g., Sun Surveyor)

🔹 Step 2: System Sizing & Design

How to Size:

1. Get the customer’s monthly usage from their bill (e.g., 150 kWh/month).
2. Convert to daily usage:
   150 ÷ 30 = 5 kWh/day
3. Assume 5 sun hours/day:
   • Needed: 5 kWh ÷ 5 hrs = 1 kW system
4. If 1 panel = 400W → need 3 panels minimum.

Choose System Type:

• Grid-Tied
• Off-Grid (requires batteries)
• Hybrid (grid + battery)

🔹 Step 3: Mounting the Structure

Steps:

1. Mark drill points on roof rafters.
2. Apply sealant before drilling.
3. Fix L-brackets using stainless bolts.
4. Attach aluminum rails to brackets.
5. Check alignment and tilt angle.

Tips:

• Use corrosion-resistant fittings.
• Space rails evenly across all panels.

🔹 Step 4: Panel Installation

Steps:

1. Lift panels carefully onto rails.
2. Align mounting holes.
3. Use clamps/clips to secure panels.
4. Tighten bolts but avoid cracking the frame.

Safety:

• Wear gloves & helmet.
• Use harness if roof is sloped.

🔹 Step 5: Electrical Wiring (DC)

Series vs. Parallel:

• Series = more voltage
• Parallel = more current

Steps:

1. Connect panel wires using MC4 connectors.
2. Route all wires into conduit.
3. Label positive (+) and negative (–).

Cables:

• Use 4mm² or 6mm² DC-rated solar cables.

🔹 Step 6: Inverter Setup

Location:

• Install near the main distribution box.
• Ensure ventilation and avoid sunlight.

Steps:

1. Connect DC input (from panels).
2. Connect AC output (to home breaker).
3. Connect grounding wire.

🔹 Step 7: Battery & Charge Controller (If Off-Grid or Hybrid)

Steps:

1. Install batteries in cool, dry location.
2. Connect charge controller:
   • Panels → Controller → Battery
3. Use proper fuses and breakers.

Battery Care:

• Never overcharge.
• Avoid deep discharging (below 20%).

🔹 Step 8: Final Wiring and Protection

What to Include:

• DC isolator (between panels and inverter)
• AC isolator (between inverter and grid)
• Properly rated breakers and fuses
• Grounding rod

Labels:

• Label all wires and isolators clearly.

🔹 Step 9: Testing and Commissioning

What to Test:

• Voltage from each panel string
• Inverter startup & error messages
• Output to AC panel

Tools:

• Multimeter
• Clamp meter
• Solar generation app (if supported)

🔹 Step 10: Monitoring & Maintenance

Ongoing Care:

• Clean panels every 1–2 months
• Check inverter regularly
• Inspect connections every 6 months

Monitoring:

🔐 Important Safety Tips

• Always turn off power before handling wires.
• Wear safety gear on roofs.
• Don’t install during rain or wet conditions.
• Secure all wiring in conduit.