Today's solar modules (panels) come with leads made using PV Wire, almost universally 10AWG, and terminate in male and female locking connectors on the positive and negative leads. Many module manufacturers use MC4 connectors made by Staubli, but not all. H4 is another type/brand. The type of connector used would be listed on the data sheet for your module. Older modules and extension wire used USE-2 wire which has thinner insulation and so smaller Outside diameter than PV Wire. Code requires the connectors be compatible, so make sure you look at the connectors used in your system if you will be repairing any wiring and installing new connectors. If your system also has optimizers or other module-level electronics, those will have similar wire and connectors. Look at the data sheet for those as well. You may have to remove some modules to get at the wiring, and if so, you may want to consider hiring a local solar professional to do this for you.
What you would need to repair chewed up wiring:
1. PV Wire, MC4 (or whatever is compatible with yours) male and female connectors and crimp pin and socket terminals
2. the crimp tool that is made for your connector/terminals (could run $100 to $280)
3. an MC4 (or other) connector release tool (plastic device to help release the mated connector halves)
4. Some PV wire management clips, like Heyco or Hellerman Tyton, to help tuck the wiring back above the module frame when done rewiring
5. Fall-protection harness, an anchor point, and appropriate ladders and other dafety gear
If modules need to be removed:
5. Tools to remove the top clamps, could be 1/2-in socket, allen wrench, etc, plus a torque wrench
6. A helper and a good plan to keep loose modules from sliding off roof
7. If your mounting system uses WEEB washers for grounding, you will want to purchase some new ones as the old ones should not be reused. If the mounting system uses integral binding pins, you won't need this.
Of course you will need to shut down the system, and if your system was installed recently and meets Rapid Shutdown requirements in NEC 2017, then high voltage would be removed from the array while shut down. If you have an older system that does not have Rapid Shutdown or only meets the 2014 code requirement for Rapid Shutdown, then the array may be hot with high voltage (up to 600V) during the day.
One last note, if there are any loose/bad crimps, improperly mated connectors, exposed conductors, wiring hanging down and touching roof surfaces, or improperly secured modules when you are done, then you will likely have problems down the road. So if you are not confident in your ability to do it correctly, maybe hire a competent installer.
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Ken Nadsady
AviSun Renewable Energy
Hudson OH
Knadsady@avisun.net------------------------------
Original Message:
Sent: 01-30-2022 07:10 AM
From: Pedro Figueroa
Subject: Replacing Solar Panel Wiring
I have raccoons getting to my roof and chewing at my solar panel wiring. Where can I purchase the wiring and install directions?
Pedro Figueroa
Home owner
Sent from Mail for Windows