{"id":81345,"date":"2024-02-05T08:49:31","date_gmt":"2024-02-04T23:19:31","guid":{"rendered":"https:\/\/www.solarquotes.com.au\/blog\/?p=81345"},"modified":"2024-02-06T19:52:50","modified_gmt":"2024-02-06T10:22:50","slug":"solar-array-cabling","status":"publish","type":"post","link":"https:\/\/www.solarquotes.com.au\/blog\/solar-array-cabling\/","title":{"rendered":"The Unseen Craftsmanship of A Good Solar Install: Array Cabling"},"content":{"rendered":"

\"residential<\/p>\n

Did you know that a staggering 90% of solar installation defects are found on the roof?<\/p>\n

Under the solar panels<\/a> is where seasoned professionals distinguish themselves, installing systems with a priority on longevity and safety. The hidden solar panel array cabling, often overlooked, speaks volumes about the installer’s dedication\u2014or lack thereof.<\/p>\n

As a Licensed Electrical Inspector (LEI) I’ve learned that array cabling is the #1 predictor of an installation’s fate. By checking the array cabling, I can usually quickly tell whether I\u2019m gonna to be inspecting a piece of craftsmanship or whether I will be onsite for the following 2 hours writing up defects.<\/p>\n

With my Dunlop Volleys on the tiles and my zoomed in iPhone on the details, I ensure that the solar systems I inspect are safe, sound, and precisely installed. Because when it comes to solar, the true test of craftsmanship is not just what you can see from quick drone shot, but what holds up against the stormy weathers of time.<\/p>\n

Here are 5 examples of array cabling which I see day to day. There are usually clues here as to the standard of the workmanship throughout the installation. Some key DOs & DON\u2019Ts. You may notice that the problem images have multiple defects, this is typical of what I see out there.<\/p>\n

#1: Running Array Cabling Behind Frame Nuts in Rail Channel<\/h2>\n

I observe this troubling shortcut way too frequently: installers running array cabling behind the frame nuts in the rail channel.<\/p>\n

It’s a gamble that places undue stress on cables due to thermal expansion and risks damage from unaware future technicians.<\/p>\n

It is also likely to damage the conductor\u2019s insulation during installation as the insulation is stripped back on the edge of the array fixing nuts.<\/p>\n

My advice? Steer clear of the rail channel.<\/strong> Secure cables externally with robust fixings like panel clips or cable ties.<\/p>\n

\"rail

Bad: <\/strong> Cable installed inside rail channel, damaged insulation during installation<\/p><\/div>\n

\"dc

Bad:<\/strong> Multiple cables run inside rail channel. It\u2019s easy to see how this could become an issue down the track with expansion & contraction due to weather conditions or if someone turns the bolt in the vicinity.<\/p><\/div>\n

\"cables

Good:<\/strong> Cables installed external to the rail channel \u2013 good job.<\/p><\/div>\n

#2: Running Cables on Catenary Wire<\/h2>\n

Using a catenary wire to fix array cabling conductors to can be a handy way to place cables where you want to when there is nothing else to fix them to. I have noticed it recently becoming quite popular.<\/p>\n

I’ve crossed paths with installations where array cabling entwines catenary wire like ivy, lacking any formal anchorage. The completed wiring loom somewhat resembles spiral pasta. This practice raises red flags.<\/p>\n

Dodgy installers defend it, expert installers just don\u2019t go there. It’s not just about meeting the bare minimum of AS3000. It’s crucial for installers to ensure their catenary wires adhere to the latest standards, which, according to AS\/NZS 5033:2021, mandate earthing unless the wires are insulated or do not make contact with DC conductors.<\/p>\n

The best practice? Use cable ties to secure the conductors to the earthed catenary wire, creating a visually tidy and stable setup that leaves no room for doubt or debate.<\/p>\n

\"spiral

Bad: <\/strong>Cables wrapped around the catenary wire in a spiral like manner, not securely fixed in position<\/p><\/div>\n

\"catenary

Good:<\/strong> Catenary wire done right \u2013 nice work<\/p><\/div>\n

#3: Pulling Cables from the Panels Tight and Under Strain<\/h2>\n

In solar installations, tension on conductors & connections is the enemy. As an LEI, I’ve witnessed the strain that overly taut cables exert on solar panel connections, risking damage to the delicate junction boxes and potentially voiding manufacturer\u2019s warranties.<\/p>\n

It’s a fine art, ensuring that each conductor from the modules is laid out with the requisite slack and supported just so, to ward off any strain and paying attention to the cable\u2019s minimum bending radii. This is especially crucial at disconnection points and at the ends of rows\u2014precision here is non-negotiable.<\/p>\n

Installers who use unskilled or unlicensed labour for all their roof work may come unstuck here as this requires skill, expertise and cannot be successfully performed by a trained monkey.<\/p>\n

\"tight

Bad: <\/strong>Cables to modules pulled tight and under strain, likely to fail over time<\/p><\/div>\n

\"dc

Good:<\/strong> Cables from modules with a nice sweeping bend \u2013 great stuff<\/p><\/div>\n

#4: Reliance of PVC Cable Ties<\/h2>\n

Navigating the unforgiving Australian sun, it’s clear that the common PVC cable ties are a false economy. They may initially save some cash, but under the relentless sun, they’re destined to fail, risking your entire solar system. I\u2019ve also heard stories of broken PVC cable ties falling into gutters and blocking drains with disastrous consequences.<\/p>\n

In my professional view, selecting stainless steel cable ties or sturdy clips is a smart move, offering durability against the brutal UV assault and temperature fluctuations. While PVC ties may be utilised to tidy up appearances, they shouldn’t ever bear the weight of securing your array conductors as the primary means.<\/p>\n

And a word to the wise: when tightening steel ties, a gentle hand is key to avoiding insulation damage and potential earth faults \u2013 good installers already know this.<\/p>\n

\"pvc

Bad: <\/strong>One PVC cable tie holding up the return cable, what happens when the tie becomes brittle and gives way?<\/p><\/div>\n

\"pvc

Good:<\/strong> PVC cable ties being used as a secondary means of fixing to tidy up \u2013 they are still useful when used right<\/p><\/div>\n

#5: Not Enough Fixing Points Causing Sagging and Unnecessary Movement in Windy Conditions<\/h2>\n

It\u2019s still too common to see not enough fixing points holding the array cabling in position. When array cables sag a bit, it\u2019s poor workmanship and may lead to unnecessary wear & tear on the conductors. When cables are in touching the roof surface, it can quickly become dangerous.<\/p>\n

It\u2019s worth noting that many years ago I saw an array conductor & MC4 connector which was never attached to the array and laying on a tin roof. I found the MC4 burnt out and the conductor now exposed and in contact with the roof surface. The roof sheets were live and I found myself having to deal with an unsafe installation.<\/p>\n

Nesting of wildlife is not uncommon under arrays. This is not an ideal situation, although can cause further complications and harm when unsecured array conductors are involved.<\/p>\n

My advice, spend a few extra moments and a few extra fixings securing conductors. Less hassle later, much safer now and it will look great. A small step which will pay off in the long run.<\/p>\n

\"sagging

Bad:<\/strong> Return cable sagging, image what it would be doing in strong winds.<\/p><\/div>\n

\"good

Good:<\/strong> Lovely array cabling \u2013 all secure & safe<\/p><\/div>\n

Conclusion<\/h2>\n

It\u2019s important to recognise that good array cabling is like the unsung hero of solar installs \u2013 it’s all about the details. It saves you from a heap of trouble down the road and keeps everything safe and reliable.<\/p>\n

So, here’s to doing it right \u2013 slap on those clips, secure those cables, and let’s make sure our solar setups stay strong for the long haul, without any hiccups. Because who wants to climb back up on the roof and fix your stuff ups?<\/p>\n","protected":false},"excerpt":{"rendered":"

Did you know that a staggering 90% of solar installation defects are found on the roof?<\/p>\n","protected":false},"author":34,"featured_media":81413,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"jetpack_post_was_ever_published":false,"_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":false,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_memberships_contains_paid_content":false,"footnotes":""},"categories":[57],"tags":[],"class_list":["post-81345","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-solar-installation","entry"],"acf":[],"yoast_head":"\nThe Unseen Craftsmanship of A Good Solar Install: Array Cabling<\/title>\n<meta name=\"description\" content=\"Uncover the hidden workmanship in solar panel installations: Why array cabling is the ultimate test of quality.\" \/>\n<meta name=\"robots\" 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With experience as a Solar Victoria auditor, CER Inspector, and a background at the Clean Energy Council (CEC), Pat is well-known in the industry. He's a devoted family man, with five children, who enjoys playing park cricket in the summer.","url":"https:\/\/www.solarquotes.com.au\/blog\/author\/pat\/"}]}},"jetpack_featured_media_url":"https:\/\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2024\/02\/array-wiring.jpg","jetpack_sharing_enabled":true,"jetpack_shortlink":"https:\/\/wp.me\/p2FF2s-la1","jetpack-related-posts":[{"id":83816,"url":"https:\/\/www.solarquotes.com.au\/blog\/defects-solar-battery-installations\/","url_meta":{"origin":81345,"position":0},"title":"Hidden Defects in Solar Battery Installations: What Inspectors Look For","author":"Pat Southwell","date":"June 3, 2024","format":false,"excerpt":"\u00a0 Solar battery installation inspections are essential. They ensure systems are safe, compliant, and function optimally. While my previous blog outlined the common defects found during battery inspections, this instalment will focus on harder-to-spot issues that are often missed. As a licensed electrical inspector, I have the training to spot\u2026","rel":"","context":"In "Solar Installation"","block_context":{"text":"Solar Installation","link":"https:\/\/www.solarquotes.com.au\/blog\/category\/solar-installation\/"},"img":{"alt_text":"battery cabling","src":"https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2024\/06\/cabling-to-hybrid-inverter.jpg?resize=350%2C200&ssl=1","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2024\/06\/cabling-to-hybrid-inverter.jpg?resize=350%2C200&ssl=1 1x, https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2024\/06\/cabling-to-hybrid-inverter.jpg?resize=525%2C300&ssl=1 1.5x, https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2024\/06\/cabling-to-hybrid-inverter.jpg?resize=700%2C400&ssl=1 2x, https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2024\/06\/cabling-to-hybrid-inverter.jpg?resize=1050%2C600&ssl=1 3x"},"classes":[]},{"id":77888,"url":"https:\/\/www.solarquotes.com.au\/blog\/disconnection-point-vs-dc-isolator\/","url_meta":{"origin":81345,"position":1},"title":"Disconnection Points Vs DC Isolators: A Solar Inspector’s Experience","author":"Pat Southwell","date":"August 29, 2023","format":false,"excerpt":"Let's shed some light on the ongoing debate between disconnection points and rooftop isolators; two critical aspects that have stirred discussions within the solar industry. As a Licenced Electrical Inspector, I'm here to look into the intriguing world of real-world solar installations in the Australian market. This is the first\u2026","rel":"","context":"In "Solar Installation"","block_context":{"text":"Solar Installation","link":"https:\/\/www.solarquotes.com.au\/blog\/category\/solar-installation\/"},"img":{"alt_text":"a disconnection point and a rooftop isolator","src":"https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2023\/08\/disconnection-point-vs-isolator.jpg?resize=350%2C200&ssl=1","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2023\/08\/disconnection-point-vs-isolator.jpg?resize=350%2C200&ssl=1 1x, https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2023\/08\/disconnection-point-vs-isolator.jpg?resize=525%2C300&ssl=1 1.5x, https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2023\/08\/disconnection-point-vs-isolator.jpg?resize=700%2C400&ssl=1 2x, https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2023\/08\/disconnection-point-vs-isolator.jpg?resize=1050%2C600&ssl=1 3x"},"classes":[]},{"id":64068,"url":"https:\/\/www.solarquotes.com.au\/blog\/challenging-solar-installation\/","url_meta":{"origin":81345,"position":2},"title":"The Most Challenging Solar Installation I Ever Did","author":"Anthony Bennett","date":"August 11, 2022","format":false,"excerpt":"(trigger warning for solar nerds - this story has a very sad ending) Finn asked me to write a post on the worst solar installation I ever had to do. The worst? Ah, let me count the ways I could interpret that\u2026 this could become a series. To pick one\u2026","rel":"","context":"In "Solar Installation"","block_context":{"text":"Solar Installation","link":"https:\/\/www.solarquotes.com.au\/blog\/category\/solar-installation\/"},"img":{"alt_text":"A very challenging solar power system installation","src":"https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2022\/08\/tough-install.jpg?resize=350%2C200&ssl=1","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2022\/08\/tough-install.jpg?resize=350%2C200&ssl=1 1x, https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2022\/08\/tough-install.jpg?resize=525%2C300&ssl=1 1.5x, https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2022\/08\/tough-install.jpg?resize=700%2C400&ssl=1 2x, https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2022\/08\/tough-install.jpg?resize=1050%2C600&ssl=1 3x"},"classes":[]},{"id":4299,"url":"https:\/\/www.solarquotes.com.au\/blog\/genius-bonkers-us-solar-company-glueing-solar-roofs-reduce-installation-costs\/","url_meta":{"origin":81345,"position":3},"title":"Genius Or Bonkers? US solar company glueing solar to roofs to reduce installation costs.","author":"Finn Peacock","date":"November 28, 2014","format":false,"excerpt":"Innovation in solar never ceases to amaze me. But I can't decide if this particular innovation is genius or totally nuts. US solar panel manufacturer Lumeta Solar\u00a0have announced a new 175W solar panel design that is super thin, with no frame, a\u00a0junction box on top instead of underneath, and get\u2026","rel":"","context":"In "Solar Panels"","block_context":{"text":"Solar Panels","link":"https:\/\/www.solarquotes.com.au\/blog\/category\/solar-panels-2\/"},"img":{"alt_text":"lumeta solar panels","src":"https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2014\/11\/lumeta-panels.jpg?resize=350%2C200","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2014\/11\/lumeta-panels.jpg?resize=350%2C200 1x, https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2014\/11\/lumeta-panels.jpg?resize=525%2C300 1.5x"},"classes":[]},{"id":86215,"url":"https:\/\/www.solarquotes.com.au\/blog\/evolution-of-solar\/","url_meta":{"origin":81345,"position":4},"title":"From Wild West to Safe & Sound: The Evolution of Australian Solar","author":"Pat Southwell","date":"September 11, 2024","format":false,"excerpt":"This article is for anyone who feels nostalgic about the early days of solar. Whether you own an old system or are an installer working on one, you might be thinking about how to maintain or upgrade it. We\u2019ll look back at the past and see how much has changed,\u2026","rel":"","context":"In "Solar Installation"","block_context":{"text":"Solar Installation","link":"https:\/\/www.solarquotes.com.au\/blog\/category\/solar-installation\/"},"img":{"alt_text":"A pv system on a house in the 1970s.","src":"https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2024\/08\/old-house-pv-system.jpg?resize=350%2C200&ssl=1","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2024\/08\/old-house-pv-system.jpg?resize=350%2C200&ssl=1 1x, https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2024\/08\/old-house-pv-system.jpg?resize=525%2C300&ssl=1 1.5x, https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2024\/08\/old-house-pv-system.jpg?resize=700%2C400&ssl=1 2x"},"classes":[]},{"id":849,"url":"https:\/\/www.solarquotes.com.au\/blog\/how-much-does-off-grid-solar-cost\/","url_meta":{"origin":81345,"position":5},"title":"How Much Does Off Grid Solar Cost?","author":"Finn Peacock","date":"January 12, 2012","format":false,"excerpt":"I had a phone call from a mate today asking for advice on buying an off grid solar system for his new house in suburban Melbourne. He was pissed off about paying the daily grid connection charge when his solar system was easily going to produce more power than he\u2026","rel":"","context":"In "Solar Panels"","block_context":{"text":"Solar Panels","link":"https:\/\/www.solarquotes.com.au\/blog\/category\/solar-panels-2\/"},"img":{"alt_text":"off grid solar system","src":"https:\/\/i0.wp.com\/www.solarquotes.com.au\/blog\/wp-content\/uploads\/2012\/01\/off-grid-solar.jpg?resize=350%2C200","width":350,"height":200},"classes":[]}],"_links":{"self":[{"href":"https:\/\/www.solarquotes.com.au\/blog\/wp-json\/wp\/v2\/posts\/81345","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.solarquotes.com.au\/blog\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.solarquotes.com.au\/blog\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.solarquotes.com.au\/blog\/wp-json\/wp\/v2\/users\/34"}],"replies":[{"embeddable":true,"href":"https:\/\/www.solarquotes.com.au\/blog\/wp-json\/wp\/v2\/comments?post=81345"}],"version-history":[{"count":10,"href":"https:\/\/www.solarquotes.com.au\/blog\/wp-json\/wp\/v2\/posts\/81345\/revisions"}],"predecessor-version":[{"id":81769,"href":"https:\/\/www.solarquotes.com.au\/blog\/wp-json\/wp\/v2\/posts\/81345\/revisions\/81769"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.solarquotes.com.au\/blog\/wp-json\/wp\/v2\/media\/81413"}],"wp:attachment":[{"href":"https:\/\/www.solarquotes.com.au\/blog\/wp-json\/wp\/v2\/media?parent=81345"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.solarquotes.com.au\/blog\/wp-json\/wp\/v2\/categories?post=81345"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.solarquotes.com.au\/blog\/wp-json\/wp\/v2\/tags?post=81345"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}