[RE-wrenches] Oddball wire request

[James Jefferson Jarvis]

Instead of un-obtanium wire, can you glue a modern j-box onto the 
module, over the top of the old j-box?

For example:
http://www.digikey.com/product-detail/en/1986175-3/A99648-ND/1980953

Or even just an outdoor rated plastic box that has the back cut out?

Dow Corning 748 Noncorrosive Silicone Sealant would be an appropriate 
RTV to use.

-James Jarvis
APRS World, LLC

On 10/9/2013 9:48 PM, Allan Sindelar wrote:
> Wrenches,
> I do a fair amount of work on ancient systems, just because there's been
> off grid here for decades. I'm rewiring several old arrays for my next
> door (meaning < 1/4 mile away) neighbor. The particular array has six
> 53W Solec modules wired as three two-module 24V pairs, on a Zomeworks
> tracker so old that it has aluminum rails and attached freon canisters
> instead of the integral square tubes. Both modules and tracker continue
> to work well, but the wiring is so degraded from sun exposure that's
> it's bare in spots, and this is what I want to fix.
>
> Each module has a tiny j-box - 3" x 3" x 7/8" deep. Each j-box has a
> single 3/8" cord grip bushing (CGB). Each bushing has two #10 conductors
> coming out of the single hole in the CGB. The O.D. of each wire is about
> the same as that of THWN. The problem is that the single hole in the CGB
> is only large enough to fit this diameter. USE-2 is too large, and
> modern PV wire is way too large.
>
> I bought a dozen replacement 3/8" CGBs from Del City, but the matching
> lock rings are too large to fit inside the j-boxes. I'd be cautious
> about using a narrow Unibit to drill an additional hole in each j-box
> anyway, given that the holes would be so close to the backsheet.
>
> The easiest solution would be to find some sunlight-resistant, wet-rated
> single-conductor wire in #10 or #12 that has an insulation O.D. about
> the same as THHN/THWN. Any ideas, please? Code is not an issue in this
> instance - I just want a solution that works.
>
> I thought about using float switch cable, which is UV-resistant,
> wet-rated, direct-burial-rated type TC. We keep plenty in stock for
> signal circuits, and it fits and is strong. The problem is that I need
> single conductors, because each module will have one series conductor
> and one output conductor, and they run to different locations.
>
> Are there any better ideas out there?
> Thanks, Allan
> --
>
> *Allan Sindelar*
> _Allan at positiveenergysolar.com_ <mailto:Allan at positiveenergysolar.com>
> NABCEP Certified PV Installation Professional
> NABCEP Certified Technical Sales Professional
> New Mexico EE98J Journeyman Electrician
> Founder, *Positive Energy, Inc.*
>
> A Certified B Corporation^TM
> 3209 Richards Lane
> Santa Fe, New Mexico 87507
> *505 424-1112 office 780-2738 cell*
> _www.positiveenergysolar.com_ <http://www.positiveenergysolar.com/>
>
>
>
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-- 
-James Jefferson Jarvis
APRS World, LLC
+1-507-454-2727
www.aprsworld.com