Commercial Solar
Power Installation

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Commercial solar power installations break down into a number of discrete elements, which could be completed sequentially as shown below, though they can also be adjusted if, for example, you wanted to complete the internal work or external works at different times to minimise disruption on site. The main elements are:

Site setup

This is setting up welfare facilities, access to the roof, installation the anchor points, take delivery of any access equipment (telehandler, MEWP etc.), get scaffolding installed, setup any health and safety systems etc. – basically get everything ready for the commercial solar power installation works to start.

Mounting System

Setting out is marking out the reference points for the mounting system to be installed from. The reference points and key dimensions would be shown on the ‘setting out drawing’ produced at the design stage. Depending on the size of the system, setting-out normally takes two engineers a day or two with a rotating laser-level, total station, a tape measure and a permanent marker pen.

Installing the mounting system is a major part of the job in terms of time taken, and normally involves installing all of the fixings to the existing roof and then the mounting rails that the solar PV panels will fix to. For ballasted systems it is a matter of getting the frames assembled in situ and then adding the required amount of ballast. For ground mount systems it is installing the main mounting posts into the ground, then assembling the mounting rails onto these.

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Cabling Systems

Fitting the cable penetration points

Getting the DC cables from the strings of solar PV panels on the outside of the building onto cable trays inside the building in a safe, neat and tidy way that doesn’t leak at any point in the future is not as straightforward as you might first think. We would consider this in detail at the design stage and specify the most appropriate method, then implement this now in preparation for running the DC cabling.

Fit the cable containment systems

‘Containment systems’ is the industry term for cable management, and generally means cable trays to route the DC cabling from the cable penetration point to the inverter, and AC cabling from the inverter to the distribution board.

Solar PV DC cabling being installed

Inspection of Solar PV panel connections

DC cabling (and earth bonding if applicable)

Next all of the DC-cabling for the strings of solar panels are run back to the cable penetration points and then to the inverter location. These cables must be supported and protected as required, and are separated by polarity on the cable trays. They are all labelled for identification and coloured red and black depending on polarity. If required, and earth bonding cables from the mounting system would be ran at this point as well.

AC cabling and comms

This is wiring between the inverter and the point that the generated electricity connects to – normally the nearest distribution board on the site. There is also a main AC isolator installed next to the inverter(s) and sometimes another at the other end of the cable before the distribution board. The communications system is normally done by connecting the inverter(s) into your onsite network, via an RJ45 / CAT 6 network cable. This normally needs some input from your onsite IT person to setup access / open firewalls etc. There are alternative methods using mobiles comms etc. for a small additional cost.

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Inverter Fit

This is the physical installation of the hardware, not the wiring. The inverters could be floor or wall-mounted, and are generally a number of modular, smaller units rather than a single large inverter. Due to their modularity, the manufacturers generally design them to be relatively easy to be moved around, with modules not weighing more than about 75 kg each.

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PV Panel Fit

The big bit. With all of the above done in preparation, this part of the commercial solar power installation is relatively quick. There is a lot of moving panels into position, connecting the optimisers and DC-cable tails and securing the cables, then clamping the panels into position. Organisation and hands-on-deck are key. There’s a significant task of managing all of the cardboard packaging, which is measured in skip-loads because every panel comes in its own box!

Inspection of Solar PV panel connections

commercial solar power installation -Roof mounted solar PV panels being secured to the fixing rails

Roof mounted solar PV panels being secured to fixing rails

Commission System

The DC-side is commissioned first, and this can even be done without the AC-side being energised. Then the AC side is commissioned – initially at a reduced power output to just check the grid connection system works correctly, then the output can be ramped up to maximum. Once working, the system will be closely monitored using the remote access over the first few weeks of operation, then the monitoring system will be setup to automatically send out performance statistics and any maintenance alerts to the nominated person (often Renewables First if we manage the system for you).

PV System Design & Consenting

Commercial Solar Power

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Commercial Solar
Power Installation

Site setup

Mounting System