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Glass Solar Panel Mounting Guide

Glass Solar Panel Mounting Guide

Glass Solar Panel Mounting Guide for Caravans, RVs, 4WDs and Boats

Framed glass solar panels sold by Solar 4 RVs are designed to provide reliable power in demanding off-grid installations, but the panel is only one part of the finished system. Long-term performance depends on how the panel frame, mounting hardware, roof or support structure, cable entry and electrical system work together.

A panel mounted in the wrong frame locations, fitted to a weak roof skin, installed without adequate ventilation or attached using an unsuitable adhesive can loosen, leak, overheat or suffer frame, cell or glass damage. On a moving vehicle or vessel, poor mounting can also create a serious safety hazard.

This guide applies to the framed glass solar panels sold by Solar 4 RVs, including our primary Exotronic panel range and selected panels from other manufacturers. Because Exotronic is our main solar-panel range, Exotronic mounting frames, brackets and related installation equipment are used throughout this guide as the preferred examples. Always confirm the requirements for the exact panel being installed, as dimensions, frame profiles, mounting-hole locations, approved clamp zones and installation limits can vary between models and manufacturers.

Multiple framed solar panels installed across the roof of an RV
A complete roof layout must account for panel support, airflow, shading, cable routing, drainage and future service access.

Important safety and scope notice

This guide provides general installation guidance and does not replace a site-specific structural assessment, electrical design or the instructions supplied with the panel, mounting hardware, roof, vehicle, vessel, adhesive or sealant.

The installer must confirm that the complete installation is suitable for the expected wind uplift, road vibration, wave impact, thermal movement, corrosion exposure and operating environment. The supporting structure, waterproofing, cable protection and electrical installation must also comply with the requirements that apply to the vehicle, vessel and installation location.

Use appropriately qualified tradespeople where required. Electrical work must be completed by a suitably qualified or licensed person where applicable. Stop the installation if the roof structure, fixing method, adhesive compatibility or mounting arrangement cannot be verified.

A solar panel produces electricity whenever light reaches it. Incorrect mounting or wiring can result in electric shock, arcing, fire, water ingress, panel detachment, damage to the vehicle or vessel, serious injury or death. Work at height also requires suitable access and fall protection. Do not install panels in strong or gusty wind.

Contents

Start with the exact panel

Do not design the mounting arrangement from the panel wattage alone. Confirm the exact panel brand and model, overall dimensions, frame depth, mass, mounting-hole positions, approved clamp zones and any model-specific clearance requirements before selecting brackets or marking the roof.

Most installations can be built around Exotronic mounting frames, brackets and accessories, but the selected components must still suit the exact panel and application. The correct solution for a compact caravan roof may be different from the arrangement required on a large motorhome, aluminium canopy, roof rack or marine hardtop. Do not assume that mounting-hole spacing, clamp zones or frame dimensions are interchangeable between panel models.

Example solar panel dimensional drawing showing overall size, frame depth and rear mounting holes
Example Exotronic product drawing showing the dimensions and factory mounting holes that must be confirmed for the exact panel model.

Treat the installation as one load path

The panel frame transfers wind, vibration and movement into its mounting holes or approved clamp zones. The brackets, rails or mounting frame then transfer those forces into the roof, rack, canopy or hardtop. Every connection in that path must be compatible and strong enough for the intended service.

Do not assess the installation using the panel's stationary weight alone. A mobile or marine installation must also account for aerodynamic uplift, braking, cornering, rough roads, corrugations, wave impacts, repeated heat cycles and flex in the supporting structure.

A roof rack or canopy load rating does not automatically confirm that the panel clamps, rail spacing or roof attachments are suitable for wind uplift. The complete installed arrangement must be assessed.

Safety before work starts

  • Plan safe roof access before lifting the panel. Use a suitable work platform, edge protection, fall prevention and other controls appropriate to the site.
  • Do not work in rain, strong wind, gusty conditions or when the roof is wet, excessively hot or unsafe to access.
  • Confirm the panel's mass and dimensions before lifting. Use enough people or suitable lifting equipment to keep the panel supported and under control.
  • Wear suitable personal protective equipment, including gloves, eye protection and protective footwear.
  • Remove watches, rings and other conductive jewellery before electrical work.
  • Keep the panel covered with an opaque cover and work in shade where practical.
  • Use insulated tools around electrical conductors and protect loose leads from contact, contamination and damage.
  • Do not connect or disconnect PV connectors under load.
  • Never stand, kneel or place tools on the panel.
  • Never lift or carry the panel by its junction box or cables.
  • Keep people clear of the area below roof work and secure tools and components against falling.

Tempered glass is strong across its surface but remains vulnerable to edge impact, twisting and concentrated loads. Do not install a panel with cracked glass, a bent or separated frame, rear-surface damage, a loose junction box, damaged cable insulation, contaminated connectors or any other visible damage.

A damaged panel may continue producing electricity in daylight. Isolate the area and have the panel assessed before handling or removal.

Plan the panel location

Create a scaled roof, rack or deck layout before drilling, bonding or ordering mounting components. Measure the actual panel rather than relying only on nominal dimensions, and allow space for brackets, rails, fasteners, cable bends, cable entry and future servicing.

Installer marking a solar panel position on a vehicle roof before mounting
Mark the complete panel, bracket and cable-entry footprint before drilling or bonding.

A suitable panel location should:

  • remain within the permitted dimensions and clearances of the vehicle or vessel;
  • avoid regular shade from air conditioners, vents, antennas, masts, roof racks and other equipment;
  • maintain the required air gap beneath the panel;
  • allow water, dust, leaves and debris to drain freely;
  • leave access for cleaning, connector inspection, fastener checks and eventual panel removal;
  • keep the panel away from exhausts, flues, engine heat, hot pipes and other heat sources;
  • protect the panel from doors, hatches, awnings, cargo, branches and moving equipment;
  • avoid creating a step, trip point or roof-access platform; and
  • provide a verified structural fixing location beneath each mounting point.

Roof edges and corners can experience higher or more turbulent wind loads than the central roof area. A forward-facing gap, raised leading edge or improvised wind deflector can also change the forces acting on the panel. Do not copy another installation without confirming that the panel size, roof shape, bracket spacing and vehicle use are comparable.

Where a bifacial or glass-glass panel is being installed, rear clearance, reflected light, rear-side shading and protection of the rear glass must also be considered. This guide does not cover frameless panels.

Verify the supporting structure

The visible roof skin may not be capable of carrying the panel loads on its own. Caravan and RV roofs can contain thin aluminium or fibreglass skins, composite sandwich panels, timber or metal framing, wiring, plumbing, insulation and unsupported voids. Canopies, roof racks and marine hardtops can also have restricted fixing zones and concentrated-load limits.

Before installation:

  • check the roof, rack, canopy, vehicle or vessel documentation for permitted mounting and modification locations;
  • identify structural members and confirm where concentrated loads and penetrations are allowed;
  • inspect for corrosion, moisture, delamination, chalking, loose paint, cracks, soft areas and previous repairs;
  • confirm that the substrate and coating are compatible with the proposed cleaner, primer, adhesive and sealant;
  • check roof, rack, axle, payload and total-mass limits where applicable;
  • locate hidden wiring, plumbing and other services before drilling; and
  • obtain written technical or engineering guidance where the existing documentation does not verify the proposed arrangement.

Do not attach a bracket or bonded mounting foot to a weak coating. A high-strength adhesive bonded to loose paint is still only as strong as the paint beneath it. Sealant also cannot compensate for an unsuitable roof structure or poorly supported fixing point.

Build a complete mounting system

Every panel should be installed as part of a complete system that includes the correct mounting points, suitable brackets or rails, compatible fasteners, adequate ventilation, corrosion control, waterproof cable entry and a maintainable cable route. For most installations, the Exotronic mounting range is the preferred starting point, provided the selected components are compatible with the exact panel and supporting structure.

Use the approved frame holes or clamp zones

Attach the panel only through its factory mounting holes or approved frame-clamping areas. Do not drill additional holes, enlarge existing holes, notch or cut the frame, fasten through the glass or allow a clamp or fastener to press against the glass.

Unapproved frame modification can weaken the panel, damage its protective finish and affect safety or warranty coverage.

Where clamps are used, they must match the frame profile and engage the frame correctly. They must not touch the glass, shade active cells, block frame drainage openings or distort the aluminium extrusion. Use the specified number of clamps and keep them within the approved zones.

More tightening force is not safer. Excessive torque can deform the frame or load the glass, while insufficient torque can allow movement. Use the torque and locking method specified for the mounting components.

Keep the panel ventilated

Framed glass panels should normally be supported above the mounting surface rather than bonded flat across the rear of the panel. The air gap allows heat to escape, reduces heat transfer into the roof, supports drainage and provides space for cable routing and inspection.

Do not seal the complete perimeter or fill the ventilation space unless the exact panel and mounting arrangement specifically require it. Where several instructions specify different minimum clearances, use the largest applicable requirement.

Prevent galvanic and stray-current corrosion

Most framed glass panels, including the Exotronic range, use an anodised aluminium frame. Galvanic corrosion can occur when aluminium is electrically connected to a dissimilar metal while moisture, saltwater or contaminated water acts as an electrolyte. Stainless-steel fasteners, steel racks, copper conductors and other metals can all form part of a corrosion circuit when they are not correctly isolated. Damage is often concentrated where the aluminium finish has been scratched, drilled, clamped or penetrated.

Stray-current corrosion is a separate electrical fault and can progress much faster than ordinary galvanic corrosion. It occurs when DC current escapes from damaged, wet or incorrectly installed wiring and returns through the panel frame, brackets, roof, vehicle chassis, vessel structure or surrounding water. Water intrusion into a poorly assembled connector, cable gland, junction, cable entry or damaged insulation can create an unintended conductive path.

Close-up of a black anodised aluminium solar panel frame corner
Protect the anodised aluminium finish and isolate the frame from incompatible metals, including through the bolts, washers and sleeves.
Close-up of a solar panel junction box, cables and PV connectors
Weather-rated parts still depend on correct connector assembly, cable support and routing that prevents water from tracking into electrical joints.

To reduce the risk:

  • Do not mount an aluminium panel frame or bracket directly against an incompatible metal unless the complete joint is specifically designed for that contact.
  • Use suitable non-conductive barriers, isolating washers, bushes or sleeves where required. Check the complete fixing: bolts, rivets, screw threads, washers and exposed edges must not bypass the isolation layer.
  • Protect drilled holes, scratches, cut edges and damaged coatings, and do not create joints that trap saltwater, dirty water or condensation.
  • Do not rely on paint, powder coating or a thin adhesive layer as the only electrical isolation unless the documented mounting system specifically permits it. Coatings can be damaged during tightening, movement or servicing.
  • Keep the PV conductors electrically separate from the panel frame and mounting structure, apart from any deliberate bonding or earthing connection required by the complete electrical design.
  • Never use the panel frame, mounting hardware, roof, vehicle chassis or vessel hull as the normal PV positive or negative current-return path.
  • Use compatible PV connectors assembled with the correct contacts, cable size and tooling. Keep connections supported, strain-relieved and away from standing water.
  • Weather-seal cable entries using components suited to the cable and surface. Replace damaged, contaminated, corroded or overheated connectors rather than attempting to make them serviceable with tape or external sealant.

Marine installations require additional attention because salt, continuous moisture, shore power, bonding arrangements and DC leakage can all contribute to corrosion. The panel frame, mounting hardware, DC negative, protective earthing, vessel bonding system, shore-power installation and sacrificial-anode system must be considered together. Do not add or remove bonding connections, protective earth conductors or galvanic-isolation equipment solely to address panel corrosion without advice from a competent marine electrician.

White aluminium oxide, pitting, blistered coatings, blackened or softened aluminium, green copper deposits, rapidly corroding fasteners, repeated corrosion shortly after installation or unexpected voltage between the panel frame and supporting structure should be treated as evidence of a mounting or electrical fault. Isolate the PV system and have both the mechanical and electrical installation inspected before returning it to service.

Use compatible fasteners and locking methods

Use fasteners, washers, backing plates and locking devices of the required grade and size. The fastening system must remain secure under vibration without crushing the panel frame, bracket or roof structure.

Do not combine spring washers, thread compound, locking nuts and excessive hand force without a documented reason. Lubricants, anti-seize products and thread compounds can change friction and therefore change the clamp force produced at a given torque.

Keep important fasteners accessible for inspection. A mounting system that cannot be checked or serviced is unsuitable for a vehicle or vessel expected to operate for many years.

Mounting methods

Exotronic mounting frames and brackets

Purpose-designed Exotronic mounting frames and brackets are our preferred solution for many caravan, RV, 4WD and marine installations. They provide a practical way to support framed glass panels while maintaining ventilation and access beneath the panel. Select a frame or bracket arrangement that matches the exact panel dimensions, frame depth, factory mounting holes or approved clamp zones, and the supporting structure.

Dry-fit the panel and mounting components before drilling or applying adhesive. Confirm that all mounting points align naturally and that the panel sits flat without forcing or twisting the frame.

The bracket-to-roof or frame-to-structure connection still requires its own verified structural and waterproofing method. A correctly fitted panel bracket does not make an unsuitable roof fixing safe.

Exotronic black aluminium solar panel bracket installed through a panel frame mounting hole
An Exotronic aluminium bracket installed through an existing frame mounting hole. The bracket-to-roof connection and metal isolation still require separate verification.
Exotronic black ABS solar panel corner and side mounting bracket kit
Exotronic ABS corner and side brackets provide a non-metallic roof interface, but the adhesive joint, panel fixing and supporting roof must still be correctly designed.

Brackets using the factory frame holes

Corner, side and Z-style brackets may be suitable where they align with the panel's factory mounting holes. Confirm the hole diameter, fastener clearance, washer arrangement and available tool access before installation.

Bracket positions must suit both the exact panel and the supporting structure. Do not move brackets to unapproved frame locations simply because a roof member is easier to reach.

Bonded mounting feet or brackets

Bonded mounting feet can reduce roof penetrations, but the adhesive joint becomes a structural part of the installation. The adhesive must be suitable for the actual bracket material, roof material, roof coating, expected loads, service temperature, UV exposure, moisture and vibration.

Do not select an adhesive from a general strength claim alone. The documented process must cover both substrates, cleaning, abrasion where permitted, primer, bond thickness, open time, application temperature, humidity, cure time and environmental exposure.

  • Prepare and test the actual roof surface, including its coating.
  • Do not bond over chalking, oxidation, loose paint, polish, wax or contamination.
  • Observe cleaner and primer flash-off times.
  • Control adhesive thickness and bracket position.
  • Keep the vehicle or vessel stationary and unloaded for the complete cure period.
  • Do not drive, tow or launch the installation before curing and inspection are complete.
  • Add mechanical retention where required by the roof, mounting design, adhesive instructions or engineering assessment.

A sealant and a structural adhesive do different jobs. A product that keeps water out is not automatically suitable for carrying aerodynamic uplift, and a structural adhesive joint may still require a separately designed weather seal.

Roof racks, canopies and marine hardtops

When mounting a panel to a roof rack, canopy or hardtop, confirm that the support frame is suitable for the panel mass and the dynamic and aerodynamic loads of the intended use.

Avoid long unsupported panel-frame spans and concentrated point loads. The support rails must be straight and coplanar so the panel is not twisted when the fasteners are tightened. Allow for controlled rack or canopy movement without allowing that movement to be transferred into the glass.

Clamps must not slide along round, smooth or coated bars. Cable routes must also remain protected from rack movement, cargo, sharp edges and branches.

Installation sequence

1. Confirm the complete design

Record the panel brand and model, Exotronic or other mounting components used, panel location, structural fixing points, fasteners, torque values, adhesive and sealant products, cable route and required cure conditions. Keep the current panel and mounting instructions with the installation records.

2. Inspect and mark the installation area

Measure the actual roof, rack or hardtop and mark structural members, mounting points, cable entry and exclusion zones. Check both sides of every proposed penetration. Stop and investigate if hidden wiring, plumbing or structure cannot be confirmed.

3. Dry-fit the complete assembly

Position the rails, brackets, mounting feet, cable entry and panel before applying adhesive or completing final tightening. Confirm that:

  • the panel sits flat without being forced;
  • the factory holes or approved clamp zones align correctly;
  • the mounting structure is straight and coplanar;
  • ventilation and drainage clearances are maintained;
  • cables can be routed without sharp bends or strain;
  • the panel can still be removed for service; and
  • no hatch, awning, cargo or roof equipment can strike the panel.

4. Prepare all bonding and sealing surfaces

Work within the permitted temperature and humidity range for the selected cleaner, primer, adhesive and sealant. Follow the complete preparation process without substituting solvents, primers or abrasive methods.

Protect prepared surfaces from dust, moisture, fingerprints and excessive delay. Do not bond to loose, chalked, wet or incompatible coatings.

Installer cleaning and preparing a vehicle roof before bonding solar panel mounts
Cleaning is only one part of preparation: the actual roof coating must also be sound and compatible with the specified cleaner, primer, adhesive and sealant.

5. Install the roof attachments

Use the required fastener quantity, backing arrangement, embedment and edge distances. Keep drilling swarf away from the panel, roof and cable entry, and protect exposed metal where required.

Weather-seal penetrations using compatible components without blocking drainage paths. For bonded feet, control the adhesive bond line and allow the full documented cure.

6. Fit the panel without twisting it

Lift the panel with enough people to keep the glass and frame supported. Place it onto the completed mounting structure and start all fasteners or clamps before final tightening.

Tighten in the required sequence using a suitable torque tool. The panel should remain flat and unstressed throughout the process. Where visual movement checks form part of the maintenance plan, apply suitable witness marks after final tightening.

7. Route and protect the cables

Support the panel cables independently so their weight and movement do not load the junction box or connectors. Use suitable solar cable, and keep it clear of sharp edges, hot surfaces, moving equipment and areas where water or debris may collect.

Secure connectors so they cannot flap, rub against the roof or remain submerged. Complete the cable entry, strain relief, protection and electrical connection in accordance with the Solar Panel Wiring Guide.

8. Allow curing, then inspect and record

Keep the vehicle or vessel stationary for the complete cure period required by every bonded or sealed joint. Inspect the installation in good light before driving, towing, launching or energising the system.

Keep photographs, product information, torque values, adhesive batch details, cure conditions and electrical test results with the vehicle or vessel records.

Commissioning checklist

Do not drive, tow, launch or energise the completed installation until every applicable item has been checked.

  • The exact panel model is suitable for the intended application.
  • The roof, rack, canopy, hardtop or supporting structure has been verified.
  • The installed panel remains within all permitted vehicle or vessel dimensions.
  • The panel position avoids regular shading, heat sources and moving equipment.
  • All brackets, rails, clamps, fasteners, adhesives and sealants are identifiable and compatible.
  • Only the factory mounting holes or approved clamp zones have been used.
  • The panel frame and glass have not been drilled, cut, notched or modified.
  • The panel sits flat and unstressed.
  • The required ventilation and drainage clearances are present.
  • Dissimilar metals have been isolated where required, and fasteners do not bypass the isolation barriers.
  • There is no unintended electrical continuity between either PV conductor and the panel frame, brackets, roof, chassis or hull.
  • Fasteners have been tightened using the specified torque and locking method.
  • Bonded joints have completed their full cure under suitable conditions.
  • Roof penetrations and cable entries are mechanically secure and weather-sealed.
  • Cables are supported, protected from abrasion and clear of heat and moving parts.
  • PV connectors are compatible, fully assembled, strain-relieved and secured away from damage and standing water.
  • Cable entries, glands and junctions are weather-sealed, dry and arranged so water cannot collect or track along the cable.
  • Polarity, open-circuit voltage and other required electrical tests have been completed safely.
  • No tools, loose fasteners, swarf or packing remain on or beneath the panel.
  • Installation photographs, torque values, cure records and test results have been retained.
  • The owner has been given an inspection and maintenance schedule.

After commissioning, check the completed installation for water ingress using a method suitable for the roof or vehicle. Do not direct high-pressure water at seals, connectors or the junction box.

Inspection and maintenance

Road vibration, salt, UV exposure, heat cycles, roof flex and impact can change an installation over time. Inspect the panel and mounting system after the first journeys, after rough-road travel, after severe weather, after an impact, after nearby roof work and before extended travel.

Marine installations and vehicles used on corrugated roads or in coastal areas should be inspected more frequently.

Check for:

  • loose, missing, rotated or corroded fasteners and clamps;
  • movement marks, fretting, distortion or cracking around brackets and roof attachments;
  • lifting, cracking, voids or contamination in bonded joints;
  • failed or separated sealant and signs of water ingress below the installation;
  • cracked glass, a bent or separated frame, delamination, discolouration or hot-spot damage;
  • a loose junction box, strained leads, damaged insulation or unsupported cables;
  • connectors, glands or cable entries that are loose, wet, contaminated, corroded, overheated or exposed to standing water;
  • white powder, pitting, blistered coatings or corrosion where the aluminium panel frame, fasteners and support structure meet;
  • damaged isolation washers, sleeves or barriers, or fasteners that electrically bridge isolated components;
  • blocked ventilation or drainage spaces; and
  • new roof equipment, cargo or damage that shades, strikes or loads the panel.

Do not automatically retighten a fastener that has moved. First determine why it loosened and inspect the bracket, locking method, mounting surface and panel frame for damage. The same principle applies to lifted adhesive joints, cracked sealant and damaged roof surfaces.

If the panel rattles, shifts, lifts, produces unusual wind noise, has broken glass or damaged wiring, smells hot or burnt, or shows water entry, stop using the installation. Secure the vehicle or vessel away from people where practical and have the system made safe and inspected. Remember that a damaged panel can remain electrically live in daylight.

Common mistakes to avoid

  • Selecting brackets before confirming the exact panel dimensions, frame profile and mounting points.
  • Copying clamp positions, air gaps or torque values from a different panel.
  • Drilling, cutting, notching or otherwise modifying the panel frame.
  • Clamping outside the approved zones or allowing a clamp to touch the glass.
  • Forcing the panel onto rails or brackets that are not straight and coplanar.
  • Attaching brackets only to a thin roof skin without confirming the supporting structure.
  • Bonding to dirty, oxidised, chalked, flaking, wet or incompatible surfaces.
  • Using a weather sealant as a structural adhesive without documented approval.
  • Driving, towing or launching before bonded joints have fully cured.
  • Relying on a rack load rating without checking wind uplift and the complete load path.
  • Bonding a framed panel flat to the roof and blocking ventilation or drainage.
  • Allowing aluminium, stainless steel and other metals to contact each other without considering galvanic corrosion.
  • Installing an isolation pad while allowing bolts, rivets or washers to bridge directly between the two metals.
  • Relying on paint, powder coating or adhesive alone to electrically isolate incompatible metals.
  • Using the panel frame, roof, chassis or hull as a PV current-return path.
  • Ignoring wet connectors, damaged insulation or poor cable entries that can cause stray-current corrosion.
  • Leaving cables to flap, rub or hang from the junction box.
  • Using incompatible PV connectors or disconnecting connectors under load.
  • Standing on the panel or using it as a roof-access platform.
  • Completing the installation without photographs, torque records or a maintenance plan.

Frequently asked questions

Can I glue a framed glass panel directly to the roof?

Normally, no. A framed glass panel should generally be supported on brackets, rails or a mounting frame that maintains ventilation, drainage and service access beneath the panel. Bonding the complete rear surface directly to the roof can trap heat, block drainage and apply loads the frame and glass were not designed to carry.

Can mounting feet be installed with adhesive only?

Only where the complete mounting arrangement is suitable for the roof substrate, coating, environmental exposure and expected loads. This applies to Exotronic mounting feet and any other bonded mounting system. The adhesive process must be fully documented, including preparation, primer, bond dimensions, cure conditions and whether secondary mechanical retention is required.

Which adhesive or sealant should I use?

There is no single product that is suitable for every roof and bracket combination. Selection depends on the roof material and coating, bracket material, expected loads, movement, temperature, UV exposure, moisture, salt and future service requirements.

Choose the product from its documented suitability for the complete joint, not from a familiar name or a general strength claim. A structural adhesive and a weather sealant may both be required.

How large should the ventilation gap be?

Use the clearance specified for the exact panel and mounting arrangement. The correct gap depends on panel construction, bracket geometry and installation environment. Do not reduce the gap simply to make the panel sit closer to the roof.

Can I drill extra holes in the aluminium frame?

No, unless written instructions for that exact panel specifically permit it. Use the factory mounting holes or approved clamp zones. Drilling or altering the frame can weaken it, damage the protective finish and affect warranty coverage.

Can any glass solar panel be installed on a caravan, 4WD or boat?

Not automatically. Confirm that the exact panel is suitable for the intended mobile or marine application and that its size, mass and mounting requirements are compatible with the available structure. The supporting and mounting design must also be suitable for the expected vibration, wind and environmental exposure.

Can poor wiring cause the panel frame or mounting system to corrode?

Yes. Damaged insulation, incorrectly assembled connectors, wet cable entries, contaminated junctions or unintended contact between a PV conductor and the frame, roof, chassis or hull can allow DC leakage. This is more accurately described as stray-current corrosion and it can cause highly localised, rapid damage. Finding and repairing the electrical fault is essential; replacing the corroded bracket or adding sealant alone will not solve it.

Will a marine galvanic isolator protect the solar-panel frame?

Not necessarily. A galvanic isolator is intended to interrupt low-voltage galvanic current travelling through the shore-power protective-earth connection. It does not correct direct contact between incompatible mounting metals, damaged PV wiring, wet connectors, unintended DC leakage or an incorrectly designed bonding system. The actual corrosion path must be identified before selecting a remedy.

Do I still need the wiring guide?

Yes. Mechanical mounting is only one part of the installation. Read the Solar Panel Wiring Guide before connecting the panel to the controller, protection devices or battery system.

Need help selecting a panel and mounting components?

Browse our fixed and framed glass solar panels and solar panel mounting brackets and frames. Our Exotronic mounting range is the preferred starting point for most installations, but every component must still match the exact panel, supporting surface and application. When installing a panel from another manufacturer, do not assume that Exotronic hole spacing, clamp locations or frame dimensions will automatically match. If compatibility cannot be confirmed from the available information, contact our team before beginning the installation.

For site-specific structural, electrical, marine-bonding or vehicle-modification decisions, use an appropriately qualified professional who can inspect the installation.

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