Peter,
I have never understood the common practice of using bare copper ground wire on and against aluminum frames and modules. It always has been a dissimilar metals issue. Just look anywhere copper has set against aluminum for awhile. We use #10 green jacketed Cu USE or XHHW conductor and strip away the jacket at each lug, using No-Ox on that section of bare wire at the lug. The wire can be tucked in to the module frames and with the PV conductors.

Kelly Keilwitz, P.E.
Whidbey Sun & Wind
Renewable Energy Systems
[email protected]
360-678-7131




On Jan 14, 2011, at 7:36 AM, Peter Parrish wrote:

One of my students who is currently responsible for standing for inspection at their company encountered a inspector who made an interesting point about
incompatible metals (i.e. copper and anodized aluminum).

The PV system in question used outdoor rated lay-in lugs to bond the rails to bare copper wire (so far so good). The ground wire was then zip- tied to the rail to carry it to the point where it entered a junction box along with
the rest of the PV conductors.

The inspector was concerned with the fact that the bare copper was in
contact with the aluminum rails and that this might cause galvanic corrosion
and subsequent failure of the grounding.

I have never encountered this issue before and I wonder if anyone else has
and what was the outcome.

As an aside: I do know that 10 AWG and 12 AWG solid bare copper wire can be purchased "pre-tinned" (maybe not tin per se, but coated). We did so by mistake. We used it up, but not before one inspector questioned its use for the purpose of grounding our system. We showed him the UL label on the spool and scraped off the coating to expose the copper core and that satisfied him. To this day I don't know if the use of this wire for grounding was
among its intended purposes.

- Peter

Peter T. Parrish, Ph.D., President
California Solar Engineering, Inc.
820 Cynthia Ave., Los Angeles, CA 90065
CA Lic. 854779, NABCEP Cert. 031806-26
[email protected]
Ph 323-258-8883, Mobile 323-839-6108, Fax 323-258-8885


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