Ground Fault using SG/DG weatherproof boxes [RE-wrenches]

[Peter Parrish]

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It would seem that there are really three distinct -- but related -- issues
being discussed under this thread: (1) MC connectors, (2) USE cable and (3)
methodologies for splicing wire in enclosures.

If USE-2 cable can hold up for 25 years on a southern California roof top,
I'm all for it. Our installers have developed tricks to quickly secure the
cable to mounting hardware that makes installation very straightforward. One
thing I do worry about is abrasion, so we make very sure to prevent the
cable from ever touching the roof surface.

MC connectors on the end of module whips sure are convenient and if one has
purchased the obscenely expensive crimping kit, one can quickly fashion
custom cables for the home run and string combining. Here is my concern: it
is very easy for the installer to leave a 10 or 20 mil gap -- that is -- not
completely seat the MC connector pair and not notice it. I also believe that
even a smaller gap -- not easily seen -- can work its way over time into a
larger gap. Does anyone know what the short term and long terms safety and
reliability consequences of a 20 mil gap? One last note: we did a project
last year with 216 modules with MC connectors and even though I personally
inspected the work, and it passed B&S inspection, we subsequently found 3
poorly seated connectors! Is it possible that there might be thousands of
poorly seated MC connectors out there -- or so we just do sloppy work?

Finally, I saw a Jeff Wolfe's post echoing my comment about Polaris-type
connectors. I am hoping to find a source to buy these in bulk quantities for
~$5/piece.

Peter Parrish
California Solar Engineering, Inc. 

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