The Critical Importance of Proper Solar Panel Earthing: Avoiding Costly Mistakes

In the world of solar installations, earthing isn’t a footnote—it’s the foundation of safety, system longevity, and performance. Still, far too often, contractors try to cut corners. A glaring example making rounds in the industry is the use of self-tapping screws as earthing jumpers—a dangerous shortcut disguised as a cost-saving measure. Let’s break down why that approach is flawed and how to do it right.

⚠️ The Risks of Improper Earthing

Using self-tapping screws or aluminum materials for grounding might look like a clever hack, but it introduces serious vulnerabilities:

• Unreliable Conductivity: Self-tapping screws are not engineered for consistent, long-term electrical contact. Vibration, corrosion, and thermal cycles degrade their conductivity, compromising the entire earthing path.

• Safety Hazards: Improper grounding invites electrical faults. During lightning events, the absence of a proper discharge path can lead to equipment destruction or, worse, pose life-threatening risks to technicians.

• Reduced System Life: Saving a sliver of budget—1–2% of total project cost—by cutting earthing corners risks the entire solar asset. It undermines performance and accelerates degradation, shrinking a system’s 25-year lifespan.

️ Common Field Failures

From field reports and industry voices, these issues repeatedly surface:

• Use of aluminum earthing lugs that corrode faster than copper, especially in humid or coastal environments.

• Improper bonding between structure and modules due to mechanical-only connections or oxidized anodized frames.

• Inadequate grounding rods or absence of site-wide equipotential bonding.

✔️ Best Practices from the Ground Up

Professionals with field-hardened experience emphasize these principles:

• Use Copper, Not Aluminum: Copper jumpers and lugs offer lower resistance and better corrosion resistance. Serrated washers are a must to break through anodized layers on module frames, ensuring metal-to-metal contact.

• Crimp It, Don’t Screw It: Connections should be crimped or soldered—not pinned with self-tapping screws. Relying on mechanical pressure alone is a gamble.

• Follow the Markings: Manufacturers provide grounding points for a reason. Always connect the earthing wire to the designated symbol on the panel using ring-type copper lugs and SS fasteners.

• Adhere to Standards: Compliance with IEC 60364, IS 3043, and similar guidelines is not optional. These standards exist to prevent exactly the kinds of failures we see too often.

• Routine Inspections: Check for corrosion, loose connections, and mechanical fatigue. Even a well-installed system can fail if neglected.

• Invest in Training: Several seasoned installers pointed out that most errors stem from lack of awareness. Training field teams on proper earthing techniques closes that gap.

Solar Earthing & Grounding – Frequently Asked Questions

Q1: Why is proper earthing essential in solar installations?
A: Earthing may appear minor, but it’s critical. Skipping or compromising on grounding can cause equipment failure, electrical hazards, and a serious drop in overall system performance. Proper grounding safeguards your investment and ensures long-term reliability, safety, and compliance.

Q2: What happens if earthing is not done properly?
A: Cutting corners on earthing can void warranties, increase risk of short circuits, and lead to expensive maintenance issues. Over time, poor grounding also degrades system efficiency and safety, making it a costly oversight.

Q3: Aren’t the panels already grounded through the GI structure? Why do we need module-to-module earthing?
A: While panels are mounted on GI structures with their own grounding, that’s not enough. Most module frames are made of anodized aluminum—which doesn’t conduct well. Proper module-to-module earthing ensures low-resistance electrical continuity that structural grounding alone can’t provide.

Q4: How should module earthing be done?
A: Panels must be earthed at the designated grounding symbol, usually on the bottom side of the aluminum frame. A copper ring-type lug should be used along with stainless steel nuts and bolts. Serrated washers are also recommended—they cut through anodized layers to ensure solid metal-to-metal contact and enhance conductivity.

Q5: Do mechanical connections count as electrical connections for grounding purposes?
A: No. Just because two components are mechanically attached doesn’t mean they’re electrically bonded. For effective grounding, dedicated electrical connections must be made using approved lugs, washers, and bolts.

Q6: What are serrated washers and why are they important?
A: Serrated washers improve both electrical and mechanical connectivity by penetrating surface oxidation or coatings (like anodized aluminum). This results in a more reliable, low-resistance bond—vital for consistent grounding performance.

Q7: Does improper earthing affect solar panel warranties?
A: Yes. Even if earthing is attempted but not done per manufacturer guidelines, it can void warranties. This is why we follow exact instructions, using approved lugs and grounding points marked on each panel.

Q8: Why do some contractors skip proper earthing?
A: Often, in a bid to cut costs or due to lack of inspection, contractors overlook grounding details. At Zorays Solar, we never compromise on safety—we use industry-standard components like lugs, sleeves, and washers to ensure compliance and long-term performance.

Raising the Bar Across the Industry

At Zorays Solar, we don’t compromise. We use dedicated earthing lugs, sleeves, serrated washers, and certified materials that meet international standards. Why? Because cutting costs at the expense of grounding is short-sighted and dangerous.

The industry needs to move beyond cost-chasing. Solar is a 25+ year commitment—and so is safety.

For more, refer to IEC/IS guidelines or consult certified professionals. Because in solar, grounding isn’t just a technical detail—it’s the difference between a safe asset and a liability.