This article is for anyone who feels nostalgic for the early days of solar energy. Whether you own an old system or work on it as an installer, you may be thinking about how to maintain or upgrade it. We look back at the past and see how much has changed and highlight the improvements that have made solar installations safer and more efficient over the years.
Reflecting on the beginnings of solar energy in Australia
Looking back, it is important to see how far the solar industry has come, particularly in Australia. Grid-connected solar systems have been around since the late 1990s, when installation practices were still evolving.
At that time, many off-grid systems were adapted and connected to the grid by licensed electricians using the AS3000 as the main guide. The standards were vague and left a lot of room for interpretation.
I remember some of the installations I did in 2009 and looking back, some of the techniques I used back then make me uncomfortable, particularly with roof insulators. Nowadays, practices and safety standards have improved significantly. Let’s examine how these standards have evolved and the key role they have played in making solar installations safer and more reliable.
This is a system from 2013 – the early days of grounding. There were teething problems as everyone got used to the new requirements.
A time of relaxed standards and learning curves
In the early days of solar energy, installation standards were much simpler than they are today. The first versions of AS/NZS 5033 and AS/NZS 4777.1, published around 2005, were short and insufficiently detailed compared to today’s comprehensive guidelines. While these early standards were fundamental, they laid the foundation for the industry’s growth and served as a guide for installers on the emerging landscape of grid-connected solar systems.
A rooftop DC isolator that has been exposed to the elements for approximately 20 years. 8 years – obvious signs of decline.
Steel cable ties became a popular method of securing array cables after 2012, when PVC cable ties were no longer approved as the primary fastener for array cables.
From grounding improvements to safer cables
Over the years, major changes in solar standards have been driven by improvements in safety and technology. In 2012, mandatory grounding of all arrays and modules, along with the use of steel cable ties and roof insulators, became a major safety improvement. These rules were introduced first in Victoria and then nationally, making facilities safer. This year, special solar cables (PV1-F) were also mandated in HD conduits for DC lines, adding another layer of safety.
A 2011 installation – the DC cabling is not rated for DC or classified as PV1-F.
In 2014, a 600 volt limit was set for household DC voltage (increased to 1000 V in recent weeks), increasing safety and imposing restricted access to commercial spaces above this limit.
Later changes included stricter rules for main circuit breakers in 2016, larger covers for roof insulators in 2018, and stricter standards for DC insulators in 2019.
A DC system greater than 600 volts – restricted access through a cage.
How separation points simplified installation
Installers welcomed the introduction of disconnects in 2022 as it eliminated the need for roof insulators and reduced installation time. However, this change also meant that DC cables could no longer run freely in roof cavities – a restriction that was initially a challenge, but was accepted for the additional safety it brings.
Conductor marking of a disconnect point – some installers needed some practice to get used to this new method. This label does not allow the plug to be removed.
These milestones have changed the way installations are carried out and presented challenges for installers and inspectors in adapting to new standards. Still, every change has helped make solar systems safer and more reliable.
Remembering the hard old days
An installer named Campbell, who has been installing solar systems for 16 years, said to me:
“I vividly remember a particularly hot summer day in 2015 when I was having difficulty installing a roof insulator on a steep roof. The job was challenging, not only because of the heat and angle, but also because the insulator added unnecessary complexity to an already difficult installation. When disconnect points were introduced in 2022, I thought back to that day and realized how much easier and safer the installation has become.”
Key insights
As solar standards have evolved, several important insights have been gained. One of them came at the beginning of the last decade with the requirement to limit optimizers or microinverters without DC isolation to 350 watts. At the time, 350W panels seemed a long way off, but soon panel sizes exceeded 330W and reached 400W, causing confusion over compliance. The rule has since been repealed, but it was a harsh lesson for the industry.
The importance of keeping up with solar standards
Looking back at the evolution of solar standards, it’s clear that the industry has come a long way since its early, less regulated days. Every change, whether a small tweak or a major overhaul, has made solar systems safer and more reliable. While the path hasn’t always been straightforward, requiring adjustments, debates and sometimes frustrating delays, these evolving standards reflect a commitment to doing things better.
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