Issues related to PV Wiring

How Others Install with Loose wiring

Unconduited wiring on ground mount. Children are naturally attracted to these structures. These unprotected wires carry up to 600 Volts DC! Children might inadvertently swing on these wires and are at risk of electrocution. This is not our installation. More examples.

Unconduited wiring on roof top. These leads will rub against abrasive roofing during windy conditions, exposing high voltage conductors. Should a ball or Frisbee become lodged near bare wires, children are at risk of electrocution. This is not our installation.

Our Installation Procedures for PV wiring with new PV Cable

In fall of 2007, the last PV manufacturer providing J-boxes discontinued the J-boxes. Below is how we install PV with the new unprtotected wiring as neatly and as securely as possible.

We build a connection box using panel mount MC connectors and providing a water tight ground connection.

We install the boxes on the PV rack and feed them with EMT and then flex.

Inside of box after wire is pulled and connected. Ground wire is routed to both rails as per manufacturer's requirements.

Completed wiring. Leads are held in place by stainless clips and stainless cable ties. This is an off-grid system with 3 times the number of leads as a grid-tie system.

Detail of how box looks with cables connected. This scheme reduces the clutter and number of splices.

Detail of how spare cable is secured to the underside of the modules. Note the stainless steel clips and ties. Most installers use plastic ties which will degrade in the elements.

PV installation procedure with junction boxes.

Wiring safely in conduit. These panels will be lowered to be parallel with the roof.

Ground mount installation procedures.

Ground mount with new style modules. We can't use conduit now so we have covered wiring with aluminum shield. Kids can not touch connectors. Many manufacturers prohibit use of unprotected wire where children or small animals can access these wire. Here is a link to the SolarWorld installation instructions. (See highlighted note on page s).

How to Quickly and Efficiently Install Non-metallic Flex Connectors

Here's how easy it is: Drop flex connector into socket...

...apply flex to connector, spin in with drill. Takes 10 seconds and about $2.50 in parts per module.