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Minimum size for consumer tails

For all ev installs so far with additional consumer unit I have used 25mm tails.

I am now looking at a ip65 consumer unit next to a meter box and pondering various options for connection between the meter box and the new consumer unit. One suggestion on a facebook group was to run 10mm tails through 25mm flexicon, but are 10mm tails acceptable.

OSG 2.2.3.1 state that consumer tails should be 25mm but no regulation  referenced and I cant find anything in BS7671, I have seen comments on other sites that some or most DNO's require 25mm tails. Looking at technical guidelines from DNO's in my area SSEN and GTC, both specify maximum length of tails but no mention of minimum size.

My thinking is that the run would be very short and the the 10mm tails would be protected by a 32A RCBO in the new consume unit, therefore very little risk.

I would like a second opinion from a group I am familiar with and based on what I have read over the last year feel I can trust.

  • There's no specific requirement in BS 7671 for meter tails - it's a matter of applying the general rules for sizing conductors.

    A downstream protective device may protect a conductor against overload, but it can't protect it against faults - for that you're reliant on whatever is upstream - in this case likely the DNO's fuse. So in theory it's just a matter of calculating based on the fault current, characteristics of the protective device and the adiabatic behaviour of the conductor.

    The other approach is not have fault protection - BS 7671 only allows that in very specific circumstances - conductors less than 3m in length, installed in such a manner to reduce the risks of faults to a minimum and reduce the the risk of fire or danger to persons to a minimum. You might get away with that sort of thing for connections to say a bus-bar chamber in industrial grade enclosure in a fireproof switch room in a controlled environment, but it's perhaps more difficult to meet those conditions in a domestic kind of setting. Note that that get-out is only for protecting the conductors against fault currents - not protecting people against shock as a result of a fault - so likely some care is still needed with regards to metallic containment/enclosures.

    The other issue is that the DNO's fuse is really outside of the scope of BS 7671 (and of your design) - and the DNOs tend to like to keep their options open - so an installation that's supplied by a 60A fuse today might be supplied by something else in the future (80A, 100A, 125A even?) or maybe even a circuit breaker rather than a fuse (as is common in the rest of the world) with likely differing characteristics, and the DNO won't want to start having to re-evaluate the on-off designs of consumer's installation every time they upgrade a fuse. Hence many DNOs recommend things like max 3m of 25mm² tails on a 100A fuse or 16mm² on a 60A fuse - and will refuse to (re)connect if smaller tails are found.

       - Andy.

  • I would use 25mm in line with accepted practice. The extra cost is trivial for such a short length. Whilst a smaller size might well be electrically safe, that counts for nothing if the DNO require 25mm and decline to connect anything smaller, either at the time or later after say a meter or fuse change.