Solar Energy Systems installation UK - lack of skills

As I researched Solar Energy systems for over a year now I discovered how little I understood the dangerous realities of Solar installations even though powered at ELV level <50Vdc.  The difference being that you are dealing with a constant current of 50 - 100's A dc.  Average Joe, maybe used to Auto/Truck 12/24Vdc  systems probably sees the system as safe - you dont get a shock (boat owners will disagree).  So the hazards of installing a dc distribution system  within a domestic house and the potential to cause disastrous fires are totally underestimated.  Even the average tradesman electrician will not have sufficient training in such matters in his CPD scheme.

To make matters worse, as a result of a question by a neighbour who want to suggest to his lad that he follow an Electrician apprenticeship, I discovered that my area (SE UK) has no regular Technical College Route pursuing CnG courses.  Apprenticeships are very rare and as a rule focus on training junior managers. 

In short, a young person cannot readily find his way in to becoming and electrical tradesman ( I have to make a distinction between the concept of a Technician here)

When you aggregate the complete installation identifying all physical components, the SLD suddenly becomes quite complex.  ie Going from Panel Arrays > optomisers > cables > marshalling boxes > Fuse links > Isolators > Master Circuit Breaker > Inverter (s) > Battery Bank > Domestic Consumer Unit > Grid resale meter > Master Isolator > standby generator > Auto Transfer Switch, Control and monitoring systems, Emergency shutdown scheme.

When you seen the numerous wannabee hopefuls going offgrid and often their lack of formal technical training they dont realise how dangerous their rough and ready installation is

I can post links to many sources of my concern here if there is sufficient interest

Robin 

Parents
  • Yes ELVs <50Vdc.  IMHO its sheer madness to be involved with MV dc Panel strings - way too dangerous  IMHO in a domestic environment, and we dont have the skilled tradesmen to recognise this type of micro grid nor is there a recognised route to upgrade to this unfamiliar but hazardous system.  Way too many unschooled wannabees playing with fireworks.  It is utter negligence by our Political leaders to allow this to continue.  They only woke up to the hazards of amateur plumbers who didnt understand flammable atmospheres till a few houses were blown up flattened.  Then British gas had to step in a institute proper training courses with local tech colleges.  Where do our Electricians get proper upgrades?  A one man jobber cant afford an apprentice (with all the paperwork and oversight involved). He will only have a family member or friend involved.

  • I would hope that most domestic installs would be done by an MCS approved, qualified electrician.  If nothing else, you'd struggle to get export payments on a DIY system.

    I've checked the logs from my system today.  It has two series strings, and each produced up to about 4A at 350V.  Nothing that an ordinary electrician couldn't handle.  It's well within the limit for LV.

  • Where do our Electricians get proper upgrades?

    There seem to be quite a few courses available - e.g. https://www.napittraining.co.uk/courses/trade/renewables, https://www.tradeskills4u.co.uk/product-category/solar-pv-courses or https://gtec.co.uk/courses/renewable-energy-training/solar-pv-training-course and lots of others many based on City & Guilds qualifications - e.g. C&G 2399. Try google.

       - Andy.

  • Octopus Energy recently updated their T&C’s to remove the requirement for an MCS Certificate, The SEG terms already had alternatives to MCS.

    I am aware of two installs without an MCS cert who do get Export payments.

    However, SEG and export are not worth the aggravation for the payback these days.

    In a good amount of cases you can get a far better installation by going to a good quality electrician rather than an MCS installer - the shocking statistics on poor installations would seem to support this. 

  • So, how many accidents and from how many installations? To be worth acting on it has to be a lot more dangerous than falling down stairs, or perhaps being run over, as for normal persons we consider that an acceptable risk.(*)

    I will point out that there are not enough accidents prevented to justify Part P, and I suspect there aren't really enough to justify gas-safe either, certainly when comparing with countries in which no such regulations exist but to suggest removing either would be political suicide, so we are stuck. I'm not sure we want another set.

    Mike.

    (*) most adults approaching middle age will know of at least one person lost in a car crash or similar. Some will know more than one. less than 1% will personally have known someone electrocuted or killed in a gas explosion - it is just so rare it ends up as headline news.

  • Pandora's box has been opened here

    Microgeneration Certification Scheme (MCS)

    https://www.gov.uk/government/publications/register-energy-devices-in-homes-or-small-businesses-guidance-for-device-owners-and-installation-contractors/register-energy-devices-in-homes-or-small-businesses-guidance-for-device-owners-and-installation-contractors

    Just when you thought that the summary dumping of Part P responsibilities on to the LABC (who had no historical involvement in electrical installations) was a complete dog's breakfast, and IMHO remains so to this day and from experiences of Landlords, widely open to brown envelopes.

    Remember gentlepersons that the domestic electrician's primary skill involves "house bashing - that's a trade term and needs years of experience" - this is not to be deprecated in anyway. The industrial electrician is an elite class holding authentic credentials in order to be allowed on site or employed by a Company.  These persons wouldnt trade their coveted positions for the Solar Wild West country.

    The average domestic electrician is a sole trader operating from home and he has to weigh the costs of trading legitimately against competing with rogue chancers who abound.  You can be a hairdresser today, slap some stick on vinyl flashy advert on the side of your van and carry on as "Instant Electrics".  Here today, gone tomorrow Strawman.

    Given that over half the cost of a Roof Panel installation comes from labour and scaffolding (mandatory ???) you can see that installation persons dont need any electrical certification (maybe half day course on how to use a ladder) and can plug in MC4s (even crimp them up).  We have the dubious practice of a young persons finishing tails under supervision of a "Competent Person"  You get the picture?

    Nowhere in any of this labyrinth of obfuscation is there any requirement for anyone to be properly trained in dc power systems. As a certified and authentic EE (not Power btw) I have spent a year looking at the problems of domestic DIY Solar systems on most of the relevant Forums covering USA/CA OZ EU and the Leisure craft/RV.

    If you want a good example of the kind of hazards you can face then the widely acclaimed site https://www.youtube.com/@OffGridGarageAustralia  will surely open your eyes.  Ignore all the bells and whistles of batteries and BMS just look behind at the electrical installation behind it all  and think about kids playing with fireworks with a can of petrol nearby.  The guy is a former IT technician and it shows a superficial grasp of dc power systems  (think of MCBs for solar panel disconnect under full sunshine  an OZ scandal since corrected when resulting in numerous alarming arc flash fires)

    (FYI the ABYC has a long history and wealth of experience  certifying electrical systems on boats, they have their own "Codes" and authorised inspectors to UL standards - if your craft is not signed off you dont get insurance and that limits where you can moor your boat - its quite draconian and there are numerous examples of fire aboard caused by electrical faults)

    There is no credible UK Solar forum to exchange User experience.  We cant even recognise the problem of highly publicised  Escooter fires from faulty products we blithely allow to be imported from Cheap Charlie  see YT https://www.youtube.com/results?search_query=escooter+fires.  The CE mark is a treacherous joke (meaning China Export)

  • I will point out that there are not enough accidents prevented to justify

    IMHO you need to look at the fallacy of that statement - how do you measure the number of accidents prevented when they didnt happen?

  • I've been looking at this recently. I'm building a house in Scotland, part of the Planning requirement is to have PV panels. (I'd have them anyway). I've had one quote, and , asking around, its a typical, maybe low price, 4kW PV, 10kW battery, supplied and fitted for £8850.

    Now, money is getting tight, so looking around, the same materials, can be bought for £5500. That's some mark up to fit those for £8850, especially as the scaffold will already be up, and the Roofer is fitting the trays to mount them (in roof system). I can fit the panels/inverter etc myself, but need the MCS sign off. Except I no longer need that, as Octopus will allow PV export with just an electricians sign off, no need for the MCS requirement, hence now, I'll be DIYing.

    MCS is also changing this year, there are far too many complaints that their eligibility requirements are too tight, rumour has it that entrance to their scheme is going to be loosened a lot. It's a same scenario in the Heat Pump world, good sole traders are not bothering trying for MCS as the costs and paperwork requirements are far too stringent, so good Designers and Installers are not fitting heat pumps, as they are not allowed to apply for the £7500 grant, yet Octopus/BG et al are fitting them with an awful design (50 deg C flow temperature) that will be fitted cheaply, but will cost the customer a lot more in the long run with their poor performance and increased electric usage.

  • Well Alan that sums up our typical bureaucratic incompetence we've come to expect. Armchair diktats from faceless mandarins.

    IMHO if you can at all then instal ground level panels.  There are numerous horror stories of roof panels - gggle and yt for info.  Tip to consider as its new build, install a cat walk tray on your roof ridge and make it accessible from a gable end by ladder. Its and unobtrusive convenience for maintenance which you will need.

    Wire each panel with its own cable thru ridge into loft space and route to a marshalling cabinet and maybe use panel optomisers. You avoid the dubious MC4 connectors (use barrel but splice ferrules and heat shrink apply si grease around metal then a 50mm length of 4:1 adhesive sleeves - these make a water resistant cover

    Beware of fake Solar cable (4mm2 solar as 6mm2 solar)

    Are you sure your location and insolation (sunshine hours) can justify the full expense of a solar system - capex vs payback time (10yrs +).  Dont believe Solar cowboy calcs. Octopus are just a shed load of accountants check very carefully TnC.  How much energy do you expect to export? Is it really worth it, store your excess as hot water or underfloor heating.  This Solar thing in Scotland has to be one of those political panjandrums  BEWARE

  • However, SEG and export are not worth the aggravation for the payback these days

    I tried doing some rough example calculations.  Say you average 2kW export for 6 hours a day.  Sign up with a supplier who offers £0.15/kWh.  That's about £657 per year.

    The panels could pay for themselves in 10 years.

  • (use barrel but splice ferrules and heat shrink apply si grease around metal then a 50mm length of 4:1 adhesive sleeves - these make a water resistant cover

    Are you sure such an arrangement would meet BS 7671 requirements for joints (526.5)?

       - Andy.

Reply
  • (use barrel but splice ferrules and heat shrink apply si grease around metal then a 50mm length of 4:1 adhesive sleeves - these make a water resistant cover

    Are you sure such an arrangement would meet BS 7671 requirements for joints (526.5)?

       - Andy.

Children
  • Are you sure such an arrangement would meet BS 7671 requirements for joints (526.5)?

    I cant justify purchase of IEE regs plus add plus the user manual, not a practising designer anymore

    can you quote the relevant excerpt 526.5 that outlaws crimped joints?

  • OBTW what I meant was "paraphrase" the relevant passage (mustnt violate copyright), but explaining/discussing an extract is ok

  • can you quote the relevant excerpt 526.5 that outlaws crimped joints?

    It wasn't the crimp I was alluding to, but the method of enclosure...

    526.5 Every termination and joint of a live conductor or a PEN conductor shall be made within one of the following or a combination thereof:

    (i) A suitable accessory complying with the appropriate product standard

    (ii)An equipment enclosure complying with the appropriate product standard

    (iii) An enclosure partially formed or completed with building material which is non-combustible when tested to BS 476-4.

    which a bit of heatshrink doesn't obviously meet, if used on its own to extend tails to reach your marshalling boxes.

       - Andy.

  • (mustnt violate copyright)

    I think we're OK with small extracts for the purpose of academic discussions Relaxed

      - Andy.

  • Surely this doesnt apply to ELV <50V systems?  You refer to heatshrink protection.  Some of the quality products seem to be very well suited to outdoors UV resistant, adhesive forms a sealed clamp on a round sheath.  I would put additional coat of Si grease on the metal parts of the barrel and around wire strands after crimping and use a 50mm length sleeve - seems belt and braces to me.  But then electrolytic corrosion can only occur with a positive and negative splice being close together in the event of a moisture path - seems remote risk.  You dont see auto wiring harnesses suffer unless in extreme circumstances.

  • Surely this doesnt apply to ELV <50V systems? 

    Just to clarify, most solar PV systems are not ELV. Typical operating voltages for small domestic systems are ~600-800Vdc, up to utility installations with open circuit voltages of 1500Vdc. Operating currents are of the order 10-20A, depending on configuration, obviously more if anything is in parallel (or if the modules are in reverse current due to mismatch or fault)

    It is also worth noting that solar PV installations rely on the measure of double or reinforced insulation, with class II equipment and insulation monitoring devices.

    The conductors, at least for sections on the array itself, should be fine wire flexible (cl5) stranded tinned conductors under that insulation, in the most part because anything on the array will be subject to frequent thermal cycling and wind movement.

    The connections will also be exposed to a wide range of temperatures (in the UK behind a panel could expect an ambient temperature from -15°C to +70°C with daily swings), are likely to see high degrees of moisture and are likely to be difficult to inspect. And yes noting the parallel thread on this topic I would expect similar in someone's loft.

    Hence the use of connectors, and connections generally, made to a standard.

  • For domestic installations, anything >50vdc is way outside my comfort zone, but thats my personal prejudice .  Aside from shock hazard,  my concern is that switchgear/fusible links etc are notoriously suspect for circuit protection under load/fault interruption.  Properly authenticated circuit breakers (as per Siemens NF) are very expensive. The Main circuit breaker with AIC 5kA can be ca £1000 for the levels you are referring to.  I was astonished to see a well known US brand which supplies a complete solar kit down to the inverter mains outlet use a rotary cam switch (typically seen on electrical panels) as a circuit breaker between the panels and the Inverter  (no internal arc quench in that design).

    At least with ELV systems you can keep the methods of last resort to hand on a shelf by the distribution board - namely a proper set of cable cutters, leather gloves, welder goggles and a plant mister bottle to spray water on an arc flash fire.  But I am old school as were fire buckets with sand.

    I have the same fear of 3 phase power and wouldnt trust any old tradesman installing that system (at least it has full industrial design system credentials behind it so I would need a professional design practice to provide  detailed installation drgs and BOM. The tradesman installer has to follow the drg to the letter and not be left to fumble his own interpretations on the back of an envelope (Ive seen this approach)

    IMHO the approach to Solar systems is very slap dash and careless, no site installation drgs, BOM, cable run iso

    Maybe the sorry tales of fast track installations reported on various Forums has given me a jaundiced view (I hate Roofers)

  • anything >50vdc is way outside my comfort zone

    From experience, I'm more worried about DC current than DC voltage. Anything more than a few (<5) amperes at 12 V or more is enough to draw an arc, and 1-2 amperes is enough to sustain it. At 5 V DC, more current is needed ... but not too much to be honest.

    Shock isn't the issue, fire, burns and arc flash can be problematic.

    I can't disagree with some of the other points that you make.

  • Anything more than a few (<5) amperes at 12 V or more is enough to draw an arc, and 1-2 amperes is enough to sustain it

    More homework needed here old chap. FYI you cant sustain an arc flash at 12 V. You will get a spark but you cant develop a sustained arc (at STP) below a certain voltage.  This is ca 20Vdc.  A welder will tell you that you can only weld with 2 car batteries 24Vdc or more  YT vids are there.

  • and anyone who has tried it will tell you that 3 car batteries strike up far better but to go easy anyway, as it does them no good at all. A few minutes non stop welding can heat the battery acid to a temperature that does irreversible damage. On the very rare occasion it is needed, I prefer to see the batteries put in a ditch or on the other side of something solid like  a vehicle, so if one does boil and vent, the scope for injury is limited, and not all on-line videos show sensible behaviour - but that is not just about welding.
    It is quite a good thing to know how to do however.

    Mike.