Protecting cables carrying high earth leakage currents located in walls and partitions against impact

I am investigating options for getting solar PV installed at home, thinking about how I would like the system installing ready for when I get installers round to quote.

The house was built with a service void (plasterboard boxing-in) which runs vertically from above the consumer unit in the garage, up through the first floor into the attic and this void already carries a number of other cables, within a safe zone created by the void running up the corner of the 1st floor room and with an electric shower mounted onto the void. Using this void to run the AC cables from the CU to the inverter in the attic, protecting the cables from the weather/elements seems a neater long term option than running conduit or cable externally, given the 25+ year life of the solar installation.

The cable route from the attic to CU is a vertical drop, but its not a perfect straight drop down the back wall due to a joist and some pipework obstructions around garage ceiling level, requiring some change in depth as it passes through the floor. There's plenty of space to pull in a flexible conduit, following the route of the existing T&E cables. The void is quite deep, over 100mm, so fixing a flexible conduit to the wall in the attic should keep it comfortably more than 50mm from the surface from the attic through to the 1st-floor floor/garage ceiling. But where it passes around the joist and pipes, where distance from the surface is difficult to confirm, though at this stage it is passing through the floor/ceiling.

If it was a regular household circuit with additional protection from a 30mA RCD then singles in flexible insulated conduit, running in the safe zone created by the room corner and shower, appears to be acceptable, but with most solar inverters having high earth leakage currents which require 100mA or 300mA RCDs to prevent nuisance tripping, then this would not provide the additional protection from a 30mA RCD as required under 522.6.202 / 415.1.1.

Therefore the protection against impact would depend on the >50mm distance from surface, which while this is fine for most of the drop, is less clear where it passes through the floor. Using the options from 522.6.204; a rigid conduit (BSEN 61386-21), trunking, armoured cables or mechanical protection appears impossible because they are all very rigid and the nature of the route requires a cable system with greater flexibility.

So the permitted options if I want to get the cables run through the void, appear to be:
a) Satisfy the installer the distance from the surface will be >50mm so the additional protection from a 30mA RCD is not required and 522.6.204 does not apply, so allowing any inverter and all conduit/cable options.
b) Specify an inverter that can operate with a 30mA RCD for additional protection, the cable will be in a safe zone so fulfilling requirements of 522.6.202/415.1.1, though this appears to substantially limit the choice of inverter (I've only found one so far). Again all flexible conduit/cable choices become acceptable.

Are there any other solutions using a flexible conduit or flexible cable that I have missed?

One potential solution that is not stated as a permitted option in the Regs and I'm unsure why not, would be to use a flexible metallic conduit earthed at each end via a fixed gland, with a separate CPC, protected by a 100mA or 300mA RCD. And as per (a), clipped to keep it >50mm as far as possible.

This would be at no more risk of mechanical damage than the T&E cables next to it. In the event of a nail strike or impact, any penetration is earthed by the continuous metal conduit so ensuring tripping of the RCD without relying on a current to flow through the nail/screw/person causing the strike. The RCD reduces the required trip current to only 100mA/300mA so even though the flexible conduit does not satisfy the requirements of a protective conductor, it only needs to carry a very low current to trip the RCD. But that doesn't appear to be an permitted option, any suggestions why this combination would not be permitted? 

Parents
  • The cable route from the attic

    Just a couple of further thoughts:

    • If the inverter is going in the loft, BS 5839-6 recommends fire (smoke or combined smoke and heat) detector in there, connected to the fire detection and alarm in the rest of the property (this would imply a minimum of interlinked smoke alarms, and the minimum requirement may be subject to devolved national requirements outside England).
    • are you having DC-coupled storage batteries installed? If so, is the attic the appropriate place for those, as they would usually be installed close to the inverter? In addition to being heavy and having some inherent fire risks, they are usually subject to a tight band of operating temperatures for efficiency, battery life, and safety.
  • I would agree the attic is a poor place to locate both an inverter and certainly a poor place for temperature sensitive and high-energy equipment like batteries, initially when I started looking I wanted these in the garage. But if protecting AC cables with a bit of earth leakage in a wall is challenging, running DC cables around the building is an order of magnitude worse, such that it almost drives you toward keeping the DC in the attic, unless you run the cables on the surface externally but even then you have a long cable drop with no form of electrical protection from the energy from the solar PV side.

    From a bit of initial investigation I can see why many of the solar installers opt for the simple solution of having inverter and batteries in the attic to minimise the DC cable run, keep it on the surface within the attic, with the AC cable down the exterior wall. It isn't particularly neat or elegant and from an equipment safety, maintenance and longevity perspective having inverters and batteries in a dusty loft subject to extreme ambient temperatures is far from ideal, but other approaches come with a lot of difficulty of how to install it in a compliant way.

    Even the recommendation of how to protect against fire is a challenge because a lot of fire safety guidance advises against smoke detectors in attics because of their sensitivity to dust / dirt / insects causing nuisance operation, so drives towards just a heat detector but that should be reasonably achievable. That said, I imagine if I want that it would be me needing to extend my existing interlinked system, I have yet to see any solar installation companies even mentioning smoke or heat detection as part of their standard packages.

  • with no form of electrical protection from the energy from the solar PV side

    Unless you go for a system with optimizers in ... certain types of optimizers have all sorts of safety features built in. In addition, to help mitigate the risk of short-circuits between L+ and L- ought to have wiring equivalent to double or reinforced insulation from each other (if installed to BS 7671:2018+A2:2022). 

    There are always innovations, and in cabling for Solar PV, although I've not seen it yet myself, I believe there's a cable type available either now or the near future, that contains the 2 or 4 insulated-and-sheathed solar DC cables in a common UV stabilized outer sheath - so apparently a 2-core or 4-core multicore Solar DC cable that the manufacturers say meets BS 7671 latest requirements: https://www.youtube.com/watch?v=OmHtcfWUI4w

    And further to innovation, there are a few other things that might be coming along. In some countries, fire service emergency isolators (I guess what we might call a firefighter's switch system) are starting to be required for certain Solar PV installations.

    Some studies into solar PV fires at inverters have identified high temperatures in lofts being a cause.

    Some insurers are providing guidelines for batteries and Solar PV, and this may bring in some other requirements.

    Research into lithium storage battery and EV battery fires is ongoing.

  • Some studies into solar PV fires at inverters have identified high temperatures in lofts being a cause.

    Is that inverters alone, or ones with batteries? If the latter, is that with lithium ion or lead-acid please?

Reply Children
  • Is that inverters alone,

    At the moment, inverters alone.

    What I don't know is whether the conductor operating temperature of cables has been taken into account in these studies, and potentially the compatibility of the cable operating temperature with the terminal operating temperatures of equipment?

  • Graham, thank you.

    A substantial part of the roof of my house is flat and the 2nd floor rooms can get quite hot in summer - say 30 deg C, maybe a little more. The difference in the loft space is that there is just bare roofing felt (and tiles) between the rafters. I have been contemplating insulating, but for energy conservation in winter.

    That notwithstanding, if the southern part of the roof were covered by PV arrays with a gap beneath them, wouldn't the roof be in shade?

    I am now thinking that before going further, it might be useful to install a temperature recorder (if there is any summer left).

  • I am now thinking that before going further, it might be useful to install a temperature recorder (if there is any summer left).

    That would be wise. Battery warranty is often temperature dependent, and both ambient and internal temperatures may be logged in the monitoring built into the battery itself.