Best Practices -- Service Upgrade / Main Panel R&R with New Solar Installs

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Phil Timmons

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DFW
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Depends on the pay and the day
Sorry if this better belongs in Solar -- or maybe there was an existing thread I did not see. . . .

What is the consensus (or what maybe should be a consensus) of "Best Practices," (not the-least-we-can-can-get-away-with) for Panel, Main, etc. Repair (Really Replace) for new Solar PV type projects.

I have beat into the Sales Guys heads -- if they "See the Rainbow" (Zinsco) or "Orange" (Federal Pacific) we should plan on replacing the panel. That part was easy. They just put it in the quote and on we go.

Where things start get messy -- old Panels (with no Main C/B -- inside or out) -- those are AT LEAST getting a New Outside Main, or Split Bus (6 "Mains") we should usually R&R.

But beyond that -- with the Solar PV disconnects also functioning as Mains (if the design call for Line Side "Taps") and the Existing Main C/B panel is inside . . . then the Mains are not grouped.

Some cities require that we also add Smoke Detectors. So far none required Arc breakers added. But many times the plans are drawn (and the quote made) with NONE of these considerations.

My bias is -- if the stuff is over 25 years old -- we should just replace it all anyway. Service Life limits and all that. At this point most customers are financed anyway, and this just becomes part of the bill, and they get the full tax credit on the entire project -- including the Service Change.

Figuring that Solar Folks are most likely going to get EVs fairly soon, as well -- I would just as soon put a New 200 Amp Service Disconnect (2020 Code) on every job, as well, and leave them a spot to add the wall charger or plug for the EV, as well.

But the Sales Folks are always biased to "Keep the Job Cost Low" -- while keeping the Sales Commissions up.

Is there anyone working towards Consensus or Best Practices for this for all of to give guidance?
 
My personal opinion is that unless the customer knows that he is going to do something in the future that it is best not to try to do a whole lot of guessing what someone might need down the road. Chances of guessing right are remote.

I don't see any reason to change out stuff that's working fine. If it's not working fine then you might want to look at changing it out before you add something to it that might add additional stress.

My personal opinion, and it's just my personal opinion, is that any substantial PV system ought to have a line side tap. I'm not sure what I would define as substantial but maybe anything 25% or more of the service rating.
 
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