Hypalon Cable [RE-wrenches]

[Joel Davidson]

Bill,

Regarding welding cable for battery cables, I have used them and like them and
have never had a failure. Perhaps Drake can list his specific reasons why
welding cable can be used so we can weigh the pluses and minuses and decide.

Regarding exposed module interconnects and quick-connects risk management, I
recently told a client that contractors who install California rebate PV systems
assume the risk for wire and quick-connects through year five after which the
customer is at risk. It is not known how many years exposed solar module
interconnect wires and quick-connectors will last. All manufacturers of UL
listed PV modules warrant materials and labor including factory installed
diodes, wiring and connectors for one year. The extended power warranty does not
include parts and labor, but if a module produces no power and the loss was not
caused by the customer, then one would assume that the manufacturer would be
required to make up the lost power with either more modules or replacement
modules.

Very few standard production solar modules fail and PV manufacturers have a
history of fixing modules with bad bypass diodes. One would assume that PV
module manufacturers would fix bad cables and connectors
if the bad part caused power loss. The customer bears the cost of removing,
boxing, shipping and re-installing modules submitted to the manufacturer under
warranty.

If clips and ties installed by the PV module manufacturer or the contractor
fail, wire and cable will move and rub against the PV modules and structure.
Wire and cable should be properly fastened with no sags. The annual visual
inspection includes looking at all wire, cable and conduit and the inspector
should be watchful for any loose wires.

Solar module interconnect wires can provide a path for rain, moisture and
condensation to enter the solar module junction box even when water-tight
fittings are used. Weep holes in the solar module junction box may be required.


Bill Brooks wrote:

> Joel,
>
> I was using interconnects as an example. Of course they are not the same
> environment. You should share your results with manufacturers on
> interconnects. Do you have some photos of the failures and corrosion you
> speak of. Sounds like very important information for the industry. Just
> because something has a listing does not guarantee that it will last
> forever. As long as it fails safe, everybody but the owner and manufacturer
> are happy.
>
> Here is a testimonial I just received from a colleague on welding cable:
>
> "When I was installing new batteries in my system
> a few months ago, I found a 1-foot piece of unlisted Excellene
> welding cable that had the insulation cracked all the way through in
> numerous places.  This cable was being operated within NEC ampacity
> guidelines (not the overinflated welding cable current ratings), and
> was no more than 11 years old-I think."
>
> This is not good news, and it also does not prove anything. Bottom line is
> that it has to pass appropriate listing tests. The NEC Code Making Panels
> will not accept it any other way. Every installer and manufacturer then have
> to make their own decisions on what they think will provide the best
> long-term performance within the realm of listed equipment and supplies.
> That's the world of electrical inspections that the grid-connected market
> lives in and many off-grid markets now live in.
>
> Bill.
>
> -----Original Message-----
> From: Joel Davidson [mailto:joeldavidson at earthlink.net]
> Sent: Saturday, July 20, 2002 10:49 AM
> To: RE-wrenches at topica.com
> Subject: Re: Hypalon Cable [RE-wrenches]
>
> Bill,
>
> Battery and module interconnects are in different environments. Since you
> brought it up, USE-2 wire and MC connectors for module interconnects have
> only
> been in use since 1990. So far connector contacts have corroded,
>
> *****snip*****
>
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