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@positiveenergysolar.com_ <mailto:al...@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
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