Comprehensive Flexible and Lightweight Solar Panel Mounting Instruction Guide

FLEXIBLE SOLAR PANEL MOUNTING INSTRUCTION GUIDE

Please read this document in full before commencing installation.

To maximise the efficiency and longevity of your new solar panels, please ensure you follow the instructions in this guide carefully.

While it seems simple to mount a flexible solar panel, common installations such as sealing around the edges of the solar panel and direct adhesion of the solar panel to a surface using Sikaflex and most other adhesives may damage the solar panel and void your warranty, please continue reading the guide for more details.

Whilst due care has been taken to ensure these methods provide a secure and permanent mounting connection, we cannot guarantee these methods will be suitable in every scenario due to variations in substrate materials, environment, and installation technique and therefore we accept no liability for any failures caused, the installer is responsible for confirming that the panel, adhesive, mounting surface, mechanical retention, cable routing, and installation method are suitable for the vehicle, expected road conditions, wind exposure, heat exposure, and local legal requirements. It is the duty of the purchaser to regularly inspect and maintain the solar panel installation.

It is normal for solar panels to heat up to above 85°C in operation or higher in fault conditions. In some cases, this can damage the substrate. Solar 4 RVs will not be liable for any damage to the substrate the panels are installed onto. We recommend using a method that creates a gap between the substrate and the module for this reason, such as the 4.6mm thickness VHB tape for spacing.

If you need clarification on any of the instructions, please contact your distributor.

Contents

Protecting the panels during installation.

Safety.

Panel Curvature (Flexibility).

Handling the Panel.

INSTALLATION ONTO A RIGID SURFACE.

STEP 1 Clean and degrease the surface area.

STEP 2 Mark the position of panels accurately.

STEP 3 Mount the panels using one of the following methods.

Method 1 – Vented Gap Kit (Sunman eArc panels with Junction Box Underneath ONLY).

Method 2 – Solar 4 RVs 2.3mm or 4.6mm High Bond Tape or 3M 2.3mm 4991 Tape.

Method 3 – Silicone Based Adhesives.

Method 4 – Onto Checker Plate (or other highly textured surfaces).

INSTALLATION ONTO ROOF RACKS.

INSTALLATION ONTO CANVAS.

Method 1 – Zippers.

Method 2 – Velcro (hook & loop).

Method 3 – Eyelets.

Example of good installs.

Example of bad installs.

Maintenance.

Pre-Installation Checklist.

Ongoing Support.

Protecting the panels during installation

IMPORTANT:

• All work should be carried out in shade or inside out of direct sunlight. Use a towel or blanket on top of the panel to reduce light exposure;
• Do not install the panels in windy or gusty conditions. Damage may result when handling or carrying a panel, or a gusty wind may lift and carry a lightweight panel;
• Do not damage the top layers or underside surfaces as the performance and longevity of the PV panel may be reduced if the surfaces are damaged;
• Do not store/stack other items underneath or on top of the panels;
• Avoid wearing sharp rings and jewellery during the installation;
• Avoid over-flexing the panels or repeatedly flexing the panel;
• Avoid installing on a sunny day as adhesive/sealant can cure too quickly or surfaces, tools and the panel can become too hot for normal handling;
• Ensure the panels are fully supported, especially in the sun. A partially supported panel will get a permanent line crease between the supported and unsupported parts of the panel;
• If sharp or heavy objects are allowed to fall onto the panels, they can cause fractures in the cells;

Safety

• Work safely at heights. Ensure you have a sturdy, secure ladder;
• Use insulated tools;
• Ensure the panels are kept covered during installation;
• Wear appropriate footwear;
• Use gloves and other PPE where appropriate;
• Seek help where needed.

Panel Curvature (Flexibility)

The panel can be curved with a gentle radius to a maximum mid-point deflection of approximately 100mm over a length of 1.5m.

There can only be one axis of bending in a panel; Longitudinal OR Transverse.

Longitudinal axis

The longitudinal bend can be convex as shown below.

Transverse axis

The image below shows a panel with multiple radii with all axis of rotation having the same direction, i.e. transverse with respect to the panel.

A real example of this is shown below

Multiple direction of axis

Panels cannot accommodate multiple radii with different directions without being stressed. For example, a longitudinal bend and a transverse bend.

Handling the Panel

Do not bend the panel excessively or repeatedly:

• The panels must not be bent more than 30 degrees per metre length, otherwise the cells and cell interconnections will be stressed;
• When being laid down both sides of the panel must be supported, either by sliding the panel along the surface or by having one person support each side;
• Panels must not be laid on a surface with one or both ends hanging over an edge. The whole panel should be supported.

Do not stress the cells or junction box during handling

• Avoid carrying panels larger than 60W horizontally (like a tray) as they will droop;
• Carry the panel vertically along the long/side edge by gripping the panel along the edge white area of the panel (not putting pressure on the cells);
• Be careful not to apply excess pressure when holding the panel along the edge cells – being on the edge there is less support for these cells;
• Do not create localised stress on the cells between thumb and fingers which could cause fracturing of the cells;
• When lifting or laying the panel down, slide the far edge of the panel over the surface so that the panel is supported by your hands and the surface;
• The junction box and cables are not handles – do not hold the weight of the panel via the junction box.

Important: Do not install if the mounting surface is unstable, damaged, flexible in multiple directions, heat-sensitive, poorly drained, contaminated, flaking, painted with weak coating, or unable to support the panel continuously.

A poorly installed panel may detach during travel and create a serious road hazard. Do not drive the vehicle until the installer has confirmed the mounting system has achieved adequate bond strength and mechanical security for the intended use.

INSTALLATION ONTO A RIGID SURFACE

If mounting your panel(s) onto a rigid surface such as an RV roof, you will need to take into consideration the thermal expansion and contraction of both the panel, the surface it’s being mounted to and the product used to adhere the two together. It is unlikely both the panel and surface will expand and contract at the same rate, therefore an adhesive with some ‘give’ will be required to absorb the difference.

UNSUITABLE Adhesive Products

• Polyurethane adhesives (i.e. Sikaflex)
• MS Polymer (i.e. Fix15)

SUITABLE Adhesive Products

• Combination of suitable* high bond double sided tape and Silicone based adhesives (i.e. SG20, Fix8)
• Silicone based adhesives (i.e. SG20, Fix8)

*Suitable means, confirmed via the manufacturer, Solar 4 RVs, or local standards, and verified compatible to the substrate by the installer. Suitability still depends on substrate condition, preparation, temperature, installation technique, load, and use environment.

You will also need to consider if the mounting surface is suitable for the purpose.

UNSUITABLE Mounting Surfaces

• Twin-wall polycarbonate sheet
• Corflute
• High Density Polyethylene (HDPE, Kingboard®, Seaboard®, Boatboard®, etc.)
• Any other surface that is unstable, damaged, or may be damaged by high temperatures, mechanical stress or trapped moisture.

SUITABLE Mounting Surface: (using an approved mounting method)

• Aluminium
• Steel
• Sealed Marine Plywood
• Fibre-glass
• Checker plate*

STEP 1 Clean and degrease the surface area

To ensure proper adhesion, all surfaces (mounting surface, back of panel and strips if being used) must be cleaned and degreased. Not doing so will weaken the bond and can cause the bond to fail.

• Clean the surfaces with slightly soapy water to remove excess grime/dirt.
• Check the surface for any loose paint or blemishes, if required rub the mounting surface with a fine or medium grit emery.
• Use a suitable degreasing product such as industrial alcohol or isopropyl alcohol.

STEP 2 Mark the position of panels accurately

Check measurements and if needed, mark the position of the panels ensuring there is no overlap.

STEP 3 Mount the panels using one of the following methods

Method 1 – Vented Gap Kit (Sunman eArc panels ONLY)

The Vented Gap Kit is available exclusively from Solar 4 RVs and consists of pre-cut strips of twin-wall polycarbonate sheeting & VHB Tape.

How To:

Lay the panel face down on a soft surface (carpet, towel, etc.) and then line the strips into position. The strips have been pre-cut to fit along the width of the panel and should be positioned so that each strip runs in between each row of cells (approx. 160mm) with the exception of the ends of the panel which have 2 strips each. Use a pencil or pen to mark where the strips will sit.

NOTE: Now that many panels use cut cells, the spacing may need to be every 2 or 3 cut cells to make the approx. 160mm distance. Normally panels 175W to 215W will use 12 strips, 4 at the ends, the 8 distributed along the middle. 100W panels will use 9 strips.

Top of panel with ‘Junction Box Under’ - Position strips around the junction box. Different panels will have slightly different junction boxes, but the principle remains the same.

Top of panel with ‘Junction Box on Top’ – Position 2 strips at the top, then 1 strip every cell gap width for the remainder of the panel.

Bottom of panel (regardless of junction box position).

Side view of panel with panel, showing double strips at top.

If your panel has the Junction Box on Top - Apply double-sided acrylic high bond foam tape to both sides of the strips and attach to the panel (leave the top layer of red plastic intact for now). Finger pressure must be used to push the tape into the surface to make sure that it has sufficient grip on the surface for adequate bond strength.

If your panel has the Junction Box Under - Apply double-sided acrylic high bond foam tape to both sides of the strips. You will need to use extra layers of tape to build up the area in which the junction box sits. Do this by applying up to 2 layers of tape on each side of the strip (4 layers of tape total per strip near the junction box). The tape will bond together. Once done, attach the strips to the panel (leave the top layer of red plastic intact for now).

Double layer of tape.

Once the strips are attached to the panel, proceed to carefully lay the panel into position and remove the red plastic layer. Gently apply pressure in between the cells, along the strips, ideally with a roller. Ensure you do not apply excessive force or push on the cells where there is no strip behind as this will damage the cell.

Wait time of tape to full strength:

20 minutes – 50% strength

1 hour – 75% strength

1 day – 90% strength

3 days – 100% strength

Apply silicone-based adhesive at the end of each strip:

The silicone must adhere to the solar panel and substrate with a minimum 15 mm² contact area at the end of each strip.

Method 2 – Solar 4 RVs 2.3mm or 4.6mm High Bond Tape or 3M 2.3mm 4991 Tape

Both above-mentioned tapes have been tested by Solar 4 RVs and deemed suitable for use in mounting our solar panels. Any other brand of tape should not be used unless prior approval has been given.

Follow the instructions in Method 1, ignoring any mention of the plastic strips.

Method 3 – Silicone Based Adhesives

If using a Silicone based adhesive such as SG20 or Fix8, apply the product in strips running the width of the panel underneath each cell gap or no more than approx. 180mm apart using lines of minimum 15 mm² contact area.

Do not seal around the edge of the panel as this will trap air under the panel which will expand as the panel heats up, causing damage to both the panel & mounting surface.

A roller may be used gently to apply pressure to the adhesive, however it is required to create a gap of 2-5mm between the panel and the substrate, therefore a spacer must be used which should be removed after adhesion, alternatively use the 2.3mm or 4.6mm tape in addition to the adhesive to create a permanent even spacer.

Method 4 – Onto Checker Plate (or other highly textured surfaces)

High bond tape does not bond well to checker plate. Some adhesives may appear to bond well at the start but then lose adhesion over time. For these reasons, we recommend that another medium such as aluminium composite (as a sheet or cut into strips) be used in between the checker plate and tape. Attach the aluminium to the checker plate with screws, pot rivets or a suitable adhesive then use of one of our standard mounting methods to mount the panel to the aluminium.

The bond area of the roof should be well drained, i.e. panels should not be bonded where water can puddle. Any droops in the surface should be fixed first.

Other textured surfaces may not be suitable for tape and require the use of this method.

INSTALLATION ONTO ROOF RACKS

If mounting on a roof rack where there is no way to support the edge of the panel, Sunman eArc panels can be stiffened by the use of C channel to the edges, and flat bar between the front and back of the panel, this additionally provides edge protection on the front and rear ends of the panel.

The flat bar is fixed to the panel using appropriate very high bond tape – if required the bar can protrude past the panel to line up with the roof racks to avoid the need to drill through the panel. The C channel slots onto the panel and flat bar and it is secured using Fix8 injected into the C channel.

The panel can be fixed to the roof rack using bolts and/or screws on the exposed aluminium section. Alternatively eyelets can be fitted at the point of sale for fixing.

INSTALLATION ONTO CANVAS

Panels can be attached to canvas providing the following guidelines are carefully adhered to:

• The canvas must provide continuous support to the panel
• Shallow radius, i.e. do not bend panel excessively
• The panel is not laid over irregularities such as structural elements, e.g. ridges/beams/tubes. These will result in the panel creasing over the structure causing premature failure.
• Panels shall not be placed over tubes supporting the canvas
• The canvas shall provide continuous support for the panel
• No part of the installed panel shall be bent by more than 10 degrees per metre length
• Panels shall not be placed onto a canvas surface where there are multiple radii with
• different axes.
• The canvas shall be kept taut
• No part of the panel shall be covered with any form of transparent material

Method 1 – Zippers

Zippers along each long edge can be used. These are sewn under the panel so that the zip material provides a cushion against the edge of the panel.

This image demonstrates the zipper method along with good execution of a cover over the edge of panel and zip.

A canvas maker’s standard industrial machine is adequate to sew zips onto the panel. You will need to provide the following instructions to your canvas maker:

• Use a YKK Marine rated zipper, UV resistant with auto locking slider
• Use a coarse stitch of at most 5-6 threads per inch
• Use polyester or PTFE based thread
• Attach zips in opposite directions so the sliders are at opposite corners of the panel

Method 2 – Velcro (hook & loop)

Marine grade stitched UV resistant Velcro must be attached under and over the panel so that the panel is in the “middle of a Velcro sandwich”. Velcro is not recommended as on removal of the panel, excessive force may damage the cells compared to zips, where less force is applied to the cells during removal.

Method 3 – Eyelets

Solar 4 RVs can punch stainless steel eyelets into the panel at various intervals (please advise at time of purchase) along the panel. Rope or similar material can then be used to tie the panel down to a supported surface.

Enough eyelets must be attached alongside each panel edge to fully support the panel. The size of panel will determine the adequate number of eyelets. Speak to our technicians to confirm based on the panel you’ve purchased.

Combination of eyelets & Rope.

Combination of eyelets, rope & rope clamp.

Example of good installs

o Panels are well supported by the canvas over the entire back surface of the panel

o Panels are well clear of the transverse beams

o Slight bending of panel in one axis

o Similar sun strength on all cells and panels as curvature is slight

o Cables are not applying any lifting, shear or twisting force on the junction box, i.e.

o Cables are laid neatly, level and are gently radiused.

o Custom “sewn-in conduit” keeps cables neat

o End of panel is well clear of the sharp roll-off at the side of the bimini

o Canvas is taut which is essential to avoid “flapping” induced mechanical stress on the panel

o Custom pocket houses a polycarbonate enclosure containing 3 fuses

o Underside location avoids rain/seawater directly on the IP67 solar connectors

o Panels can be easily removed as connectors are used

Example of bad installs

o Panels have an obvious crease which will cause stress on the cells

o Plastic cover over panels traps excess heat and moisture

In this example, the bending over the tube led to fracturing of the cells and produced a hot spot within months of installation.

x Panels have an obvious crease which will cause stress on the cells

x Panels are flexing in multiple directions causing increased stress on the cells

Maintenance Schedule

Inspect the solar panel installation:

• After the first trip
• After the first month
• At least every 12 months thereafter
• After off-road travel, storms, extreme heat, roof cleaning, impact, or any event that may affect the installation

During each inspection, check for:

• Lifting edges, loose tape, failed adhesive, or movement of the panel
• Cracks, creases, delamination, bubbling, discolouration, or hot spots
• Water pooling under or around the panel
• Damage to the roof or mounting substrate
• Cable movement, rubbing, sharp bends, or strain on the junction box
• Loose, corroded, dirty, or damaged connectors
• Dirt, salt, sap, bird droppings, or debris on the panel surface
• Corrosion of brackets, attachment points, substrate or panel

Clean the panel regularly using clean water, neutral soap, and a soft sponge or cloth. Do not use harsh chemicals, abrasive pads, pressure washers, or solvents unless specifically approved.

In marine, coastal, dusty, or high-salt environments, wash the panel and connectors more frequently with fresh water to reduce salt and contaminant build up.

Do not continue using the panel if it shows signs of mechanical damage, electrical damage, lifting, overheating, or unsafe cable strain. Rectify the issue before further travel or operation.

Pre-Installation Checklist

Before installing the solar panel, confirm:

• The correct panel model and installation guide have been checked.
• The panel has been inspected for damage before installation.
• The installer has confirmed the adhesive/tape cure time and will not drive the vehicle before adequate bond strength has been achieved.
• The mounting surface is rigid, stable, clean, dry, and suitable for the installation method.
• The mounting surface is not damaged, unstable, heat-sensitive, poorly drained, or likely to trap moisture.
• The mounting surface and back of the panel have been cleaned and degreased.
• The adhesive, tape, or mounting system is compatible with both the panel and mounting surface.
• The panel will be fully supported and will not be installed over gaps, ridges, tubes, sharp edges, or unsupported areas.
• The panel will not be bent beyond the limits stated in this guide.
• The panel will not be sealed around the edges.
• Full-surface adhesive bonding will not be used.
• Cables will be routed without pulling, twisting, rubbing, or placing strain on the junction box.
• Cable entry points and connectors will be protected from water ingress and mechanical damage.
• The installer has considered wind load, road vibration, heat exposure, roof curvature, and expected use conditions.
• The installation method complies with applicable laws, regulations, and vehicle/manufacturer requirements.
• Photos will be taken before, during, and after installation for future reference.

Ongoing Support

Solar 4 RVs is proud to offer a support service beyond the purchase of your solar panels. If you require further technical support, please feel free to contact us. We are happy to help!