Module construction [RE-wrenches]

[Steve Willey, Backwoods Solar]

Phil, we have sold Siemens and Solarex for years and I usually choose
Siemens to install for my own uses because of the junction box issue.  The
replaceable strip in Solarex saved the day only once in 10 years.

Steve Willey   www.backwoodssolar.com
Backwoods Solar Electric Systems
A catalog business on a mountain
2 miles from utility lines,
powered entirely by our catalog products.
IF UTILITY POWER IS 1/2 MILE OR MORE FROM YOUR SITE,
get our free 160 page solar-electric Planning Guide/Catalog.
(Your postal address required - Our list is never given or sold).
Phone(208)263-4290  Fax (208) 265-4788  in Idaho, USA


----- Original Message -----
From: Phil Undercuffler <phil at positivenergy.com>
To: Wrenches <RE-wrenches at topica.com>; <tovellrs at bp.com>
Sent: Tuesday, November 28, 2000 11:36 AM
Subject: Module construction [RE-wrenches]


Has anyone else noted a downward spiral in the construction quality of new
modules?

For the past few years I've thought the BP line had the best construction
and features in the market.  The j-boxes were solid, the terminals allowed
wiring flexibility with assured grip (I'm blanking from my memory those
terrible early euro push-in terminals), they came with two weathertite
strain reliefs (although they chose the location of the first).  The covers
stayed with the module on a hinge, unless you wished to remove them with a
finger poke.  The covers snapped shut and stayed shut on their own, allowing
you to make up the wiring and screw the covers closed on punchlist day.  The
rails of the frame had a ridge that kept the bolt head from spinning.

Well, I just picked up my first of the new, post-Solarex-buyout 85s.  Gone
are everything I liked, replaced with "uh, gosh, where'd that pile of module
covers go to?"  I'm buying strain reliefs (at the only local supplier that
stocks them) by the case, and his computer only orders them onesy-twosey.
The terminal strip is that wiggle strip that Solarex has used for years that
comes loose on half the modules I see in the field on repairs.  Seems that
the dog-ear clips that hold the strip in place can suffer from plastic
fatigue, and the glob of silly-cone that they put under it sticks to
everything but the plastic terminal strip.  The nice bolt-retaining ridge is
gone, in favor of a plain thin flange.

If you get AstroPower's 120 watt flagship, in order to get the cover on you
use two hands to roll an O ring tentatively into a thin groove, quickly
smash it up against the j-box, grab the little loose screws with your third
hand, reach down to your toolbelt and grab your driver with the fourth
hand......and you get that same thin flange on the frame to boot.

If you use Photowatt's 48 watt modules, their only connection point was a
1/4" male pushon terminal.  We only buy quality crimp terminals here in our
shop, but I've seen more than one of these installed with cheap
WalMart/AutoZone terminals that have come unrolled and loose.  What kind of
small system future "success" stories are we breeding here?
Now, don't get me wrong.  I know we've come lightyears since the days of the
Arco 16-2000s and their exposed studs that always break off, or the old
Siemens panels with 1 1/2" J-boxes on both ends.  But it does seem as if the
module manufacturers are now replacing quality with cheeze in a race to a
price point.

So what do I want?  A good, high-quality j-box made to withstand the
weather, that doesn't crack when the KOs are popped out of it.  A cover that
stays with the module, unless you wish to remove it.  Terminal strips that
easily accept 8awg wire, with a positive grip that holds through thermal
cycling.  A positive, secure seal without lost screws and o-rings.  A frame
that doesn't deflect when the bolts are tightened.  A panel that makes its
rated output not only in the first year, but ten years after (those 20 yr
warrantees aren't worth much without a way to easily test output--measuring
open circuit voltage and short circuit current won't do).  How about a
grounding point in the j-box as well as on the frame!  Series fuses in the
j-box!  Higher series fuse ratings to allow parallel connections?  What's
your wish list?

Does anyone have a recommendation of a panel that is easy to install,
maintains its output and holds up over time?
Phil
Positive Energy

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To send a message:
 RE-wrenches at topica.com

The archive of previous messages: 
 http://www.topica.com/lists/RE-wrenches/

To unsubscribe send a message to: 
 RE-wrenches-unsubscribe at topica.com

To check out the other RE-Wrench participants:
 www.mrsharkey.com/wrenches/index.html

Hosted by Home Power magazine: 
 www.homepower.com

For info contact list moderator by email:
 michael.welch at homepower.com

___________________________________________________________
T O P I C A  http://www.topica.com/t/17
Newsletters, Tips and Discussions on Your Favorite Topics