Solar PV installations Flat roof new build.

I am the Director of the management company and have recently come across Solar PV installations on flat roofs where the cables and MC4 connectors are exposed to elements. 

Is that allowed?

They are part of a brand new developments. We still have NHBC guarantee. 

Solar PV installation was causing all kinds of problems with functionality and output. Can someone help? 

Thanks.

Parents
  • Generally, MC 4 connectors from  reputable makes (Stäubli come to mind, there are many other makes) have an environmental rating of IP67 but only when the correct cable diameter is used and the glands are done up as per the instructions. This means they are then fine for short periods of immersion. However,  generally cables and connectors left in the sun and the wind and the rain, will not last as long as the same part under some sort of shelter, even if it is just tucked under the panel, and I'd certainly expect things to be neatly tied up and not flapping about in the open or able to be trodden on or tripped over.

    Apart from mis- assembly , as alluded above, the other problem  is if they have been mated while damp, as then that sealing works against you and the ingredients for corrosion are sealed in, instead of out.


    What sort of problems are you seeing - it is quite possible that the connectors are not the real problem, but rather like seeing mismatched screw heads on door handles can be a flag to check the rest of the woodwork, a sloppy approach to what you can see, may indicate the same (lack of) attention to detail in other areas less obvious.

    Mike.

  • That roof top weed pond reminds me why truly flat roofs are not supposed to exist according to building control.

    Apparently some are .. I recall something on the TV where the (German?) installers had deliberately installed the deck level with upstands on the outlets -  the idea being to trap a layer of water on the roof to act as a UV barrier to protect the membrane ...  it does require an extraordinarily good seal on things though. I suspect that's wasn't the intention in this case however.

       - Andy.

  • To be honest, all panels stops functioning when the full sun hits and works partially in the winter. 

    Definitely something very wrong there then. But hard to tell from this distance what the cause might be - could be insulation faults on the d.c. side or an undersized inverter shutting down when it's overloaded, or any one of a dozen possibilities.

       - Andy.

  • panels stops functioning when the full sun hits and works partially in the winter. 

    I will suggest  that alone is a good enough reason to get the installers back to explain themselves.

    The electronics will hopefully produce a log of error codes that can be read to work out why in more detail, but that may need kit you do not have.

    At the risk of the first class idiot question, with respect to the panel tilt, which way is south?

    Mike

    having realised purpose of the buckets, connectors are not designed for that sort of long term immersion. Cable basket on some more of those concrete blocks may be worth considering,  (https://www.tlc-direct.co.uk/Technical/DataSheets/Univolt/Univolt_PVC_Tray_Guide.pdf )but ideally the roof needs to slope towards an unblocked drain!!

  • I can confirm that upstands on the outlets are not sealed properly. 

  • To be honest, all panels stops functioning when the full sun hits and works partially in the winter.

    You need someone who can check the error logs on the inverter(s).

    My suspicion is an over-voltage trip on the AC side.  If the wiring is under-sized or too long anywhere between the inverter and the local transformer, it can pull the local voltage so high that the inverter shuts down.


    You do realise that if you're going to repair the roof, then you're going to have to take all the panels off? Maybe that would be a good time to tidy up the wiring.

  • That is why I am trying to figure out if the installations and cabling can be left open to elements in this way laying on the flat roof or not? Regardless of how robust the cables are made, my intention is to ask this group if the best practices for cabling are followed or not. 
    If any aspect of regulation and safety aspect missed. Not to mention the trip hazard. 

  • And if that is the case, the over-voltage trip level is something that within limits can be adjusted by the installer, as a software parameter.

  • The installers for Solar PV have closed their business. Its the developers still in business. Got 4 roof top installations, 2 towards South, 1 East and 1 SE (installations behind lift shafts so in shading basically). Entire roofs and the falls are not designed correctly and that is why we have ponding. 

  • I agree Simon and that is the best case. Hoping for NHBC to approve that. They are looking into the roof situation. 

    And they asked us under what wiring regulations and standards that the panels does not meet the standards? I came across BS 7671 but I do not have the technical knowledge. I was told this is the best place to get some clarity. 

  • And I was told because of the installation and orientation, a wrong inverter was installed. It is Afore string inverter 10KW but the panels are set for 8 KW

Reply Children
  • inverter 10KW but the panels are set for 8 KW

    That doesn't sound disastrous. The larger the inverter the greater the losses (as an absolute figure) so it's common to size the inverter to the peak rating of the panels, or even a little less(!) (my system has 2.14kWp of panels but only a 2kW inverter)  - but inverters still work perfectly well with reduced output from the panels (as happens 90+%of the time anyway as the sky isn't perfectly clear or the sun isn't at its zenith) - so 8kW of panels feeding a 10kW inverter should still work reasonably well - even if the losses a little higher than the ideal and so the final output is a percent or two lower.

       - Andy.