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| Use only 600 volt wire. Lamp cord, extension cords are not rated 600 volt. Use copper wire only. Aluminum wire is fire risk and should be avoided or installed by professional. 30 amp breaker use 10 gauge / 120-240 volt 30 amp outlet can be installed on 30 amp breaker only/ use 10 gauge wire ... cannot be connected to 15-20-40 amp breaker.  Orange/ #10 gauge wire, with ground ... 30 amp capacity. Safe maximum: 30 x 80% = 24 amps. Buy: 10-2 gauge/ 30 amp 10-3/ 30 amp Southwire electric tools |
Yellow
12 gauge 20 amp 120 volt 20 amp outlet can be installed on 20 amp breaker, but not 15 amp breaker/ use 12 ga wire. ... cannot be connected to 30-40 amp breaker. 1  Yellow/ #12 gauge wire, with ground ... 20 amp capacity. Safe maximum 16 amps. Buy: 12-2 gauge/ 20 amp 12-3/ 20 amp NMB is house wiring UF is underground Rolls of stranded wire HOOK UP Wires |
White
14 gauge 15 amp 120 volt 15 amp outlet, AFCI, GFCI, timer, switch etc can be installed on 15 or 20 amp breaker. Never connect 15 gauge wire to 20-30-40 amp breaker.  White/ #14 gauge wire, with ground ... 15 amp capacity. Safe maximum 12 amps. Buy: 14-2 gauge/ 15 amp 14-3/ 15 amp NMB is house wiring UF is underground |
| 50-60
amp breaker use 6 gauge / 240 volt 50 outlet can be installed on 50 amp breaker only  Buy: 6-2 wire Southwire electric tools NMB is house wiring UF is underground |
40-50
amp breaker use 8 gauge / 240 volt 40 amp outlet can be installed on 40 or 50 amp breaker only  Buy: 8-2 wire Southwire electric tools NMB is house wiring UF is underground |
  Copper ground wire. Every device, load, metal enclosure etc must be grounded. Ground wire must be continuous throughout installation, never switched on-off, never used as a Neutral wire. Generally ... use same size as other wire in circuit Buy: 12 gauge copper ground wire Ground wire Green ground wire Ground pigtails Ground rods/ ground clamps at Amazon |
 Non metallic flexible cables must carry ground wire, but do not have hazard of short circuit causing injury from shock. Armored steel cable can be used as a grounded connection, and will protect wires from damage. Metal can be energized from an insulation failure. All conduit ...metal, plastic ... flexible and rigid ... must be attached to structure, and attached to enclosures, boxes. Movement, damage and deterioration are major cause of electrical failure. Buy: Non-metallic flexible conduit Power whip Armored cable Southwire armored cable cutter Pull boxes |
 Electrical tools must be insulated. Always best to disconnect power, but insulation failure, lack of proper grounding, grounded neutral, lack of GFCI, out-of-code wiring, generator operating without transfer switch, and other problems still pose a risk to anyone working on electric power ... even when breaker is off. Buy: Electrician tools kits KLEIN TOOLS Tools kits IRWIN tools KNIPEX Telephone cable knife Low Voltage Mounting Bracket for Telephone |
Push-on wire connectors in place of twist-on connectorsBuy:Push on wire connectors Amazon Red 3P connector for 10-14 gauge wire Lever connectors for stranded wire at Amazon HOOK UP Wires |
 Protect wiring from damage Use nipper instead of pliers or screwdriver for removing staples (and nails). Do not damage cable or wires inside cable. -Code says: Cable SHALL BE secured without damage to the outer covering. NEC sec. 336-15 Buy End cutting nippers at Amazon |
  Electrically insulated tools When removing insulation from wire, do NOT score or put cuts on surface of copper wire. Doing so increases resistance and heat on wire and creates possible weak point. Buy tools: KLEIN TOOLS Wire strippers at Amazon Electric Wire Stripping Machine Linesman pliers Utility knife at Amazon |
 Multimeters Voltage is tested across two separate wires. Ohms or resistance is tested across both ends of same wire. Amperage is tested along one or two points on same wire. Buy: Analog multimeter Multimeters at Amazon Klein multimeter Electric testers at Amazon Clampmeter for testing amp flow on line |
 GFCI circuit breaker A GFCI circuit breaker will protect all boxes on circuit. Circuit must be grounded. Ground wire must be continuous and connected to each piece of equipment. White wire on circuit breaker must be connected to Neutral busbar inside the breaker panel. Buy GFCI circuit breakers |
Push down 1" wide Push down breaker Plug-in breaker Buy single-pole: Choose from 15 to 60 amp Eaton CL series Siemens 15-60 amp Single-pole tandem breaker Tandem breakers |
Push down 2" wide Push down breaker Plug-in breakers Buy double-pole: Choose from 15 to 125 amp Choose from 15 amp to 200 amp Eaton CL series circuit breaker Siemens circuit breaker Double pole GFCI |
 250W Renogy mono-crystalline panel Buy Bundles; 4 panels 250 watt at Amazon $1275 6 panels 250 watt at Amazon 10 panels 250 watt at Amazon 20 panels 250 watt at Amazon Solar panel connectors Buy solar panels at Amazon |
Panels
are 250 watt renology Optimum operating voltage 30.1 V Vmp Optimum operating current 8.32 A Imp each panel Question: 6 panels in a string will produce 8.32 amps? and 180.6 volts? Because the panels are like D-batteries end-to-end in series ... the voltage increases, but amperage stays the same. 2 strings with 6 panels each, combined or put together ... is like putting D-batteries in parallel... the amperage increases but voltage remains the same So putting together 2 strings of 6 panels each will produce 16.64 amps and 180.6 volts? Answer Adding panels in series increases voltage, amps unchanged. Adding strings in parallel increases amps and leaves voltage same. Resource: Following link has detailed information about DC DC-circuit-breakers. |
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String is
several panels wired in series, with + connect to - on each panel. Each panel has + wire and - wire Connect the + on first panel to - on next panel Caution: Do not connect solar panels with panel facing sun, or there will be electric power on the wires. Resource: DC fuses and circuit breakers |
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Array Strings can be combined into arrays The + wires are combined together in distribution block or a combiner. The - wires are also combined together. Both + and - are separate from each other. Wire size Standard wire gauge apply to AC or DC. Single string 6 panels might produce 22 amps. 22 amps, you use #10 wire up to 30 amps. Three strings of 6 panels combined, might produce 66 amps on the + wire, so larger wire size is needed. For example #4 wire up to 70 amps. Resources: Wire sizes and amp ratings Building a combiner box .pdf |
 Larger image |
Array =
all panels combined Flow of power is + to - With DC power, electrons flow from Positive to negative. Negative is grounded. Switchgear (circuit breaker, fuse, power disconnect etc) is always connected to positive. |
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PV
solar power resistance During high solar conditions, Low resistance harvests more electric output During low solar, Higher resistance harvests more electric output Optimal resistance (pink line on graph) is reverse of sunshine or solar output (in red) To maximize array, the correct number of strings must be calculated Graph and calculations courtesy of Network Nerdvana |
| Array: Different string
configurations result in
different resistance
To maximize solar harvest: Low solar and high solar conditions require different resistances |
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| Calculate number of strings in array | During
high solar conditions, Low resistances harvests more electric output During low solar, Higher resistance harvests more electric output |
| 1
string of 12 panels Best for lowest solar Same wattage, different resistance in Ohms |
Array
configurations. Renogy 250 watt 30.1 Vmp, 8.32 Imp.
PV Array Wmp = 12 * 250 = 3000 watts. 1) 12 panels in series. 1 string: 30.1 Vmp * 12 = 361.2 Vmp 8.32 Imp * 1 = 8.32 Imp Zmp = 361.2 Vmp / 8.32 Imp = 43.4 Ohms |
| 2 strings
of 6 panels Good for low solar Same wattage, different resistance in Ohms |
Array
configurations. Renogy 250 watt 30.1 Vmp, 8.32 Imp.
PV Array Wmp = 12 * 250 = 3000 watts. 2) 6 panels in series. 2 strings: 30.1 Vmp * 6 = 180.6 Vmp 8.32 Imp * 2 = 16.64 Imp Zmp = 180.6 Vmp / 16.64 Imp = 10.8 Ohms |
| 3 strings
of 4 panels Good for medium solar Same wattage, different resistance in Ohms |
Array
configurations. Renogy 250 watt 30.1 Vmp, 8.32 Imp.
PV Array Wmp = 12 * 250 = 3000 watts. 3) 4 panels in series. 3 strings: 30.1 Vmp * 4 = 120.4 Vmp 8.32 Imp * 3 = 24.96 Imp Zmp = 120.4 Vmp / 24.96 Imp = 4.82 Ohms |
| 4
strings
of 3 panels Good for medium solar Same wattage, different resistance in Ohms |
Array
configurations. Renogy 250 watt 30.1 Vmp, 8.32 Imp.
PV Array Wmp = 12 * 250 = 3000 watts. 4) 3 panels in series. 4 strings: 30.1 Vmp * 3 = 90.3 Vmp 8.32 Imp * 4 = 33.28 Imp Zmp = 90.3 Vmp / 33.28 Imp = 2.71 Ohms |
| 6 strings
of 2 panels Good for high solar Same wattage, different resistance in Ohms |
Array
configurations. Renogy 250 watt 30.1 Vmp, 8.32 Imp.
PV Array Wmp = 12 * 250 = 3000 watts. 5) 2 panels in series. 6 strings: 30.1 Vmp * 2 = 60.2 Vmp 8.32 Imp * 6 = 49.92 Imp Zmp = 60.2 Vmp / 49.92 Imp = 1.21 Ohms |
| 12
strings
of 1 panel Best for highest solar Same wattage, different resistance in Ohms |
Array
configurations. Renogy 250 watt 30.1 Vmp, 8.32 Imp.
PV Array Wmp = 12 * 250 = 3000 watts. 6) 1 panel in series. 12 strings: 30.1 Vmp * 1 = 30.1 Vmp 8.32 Imp * 12 = 99.84 Imp Zmp = 30.1 Vmp / 99.84 Imp = 0.301 Ohms |
| Commercial
solar collection arrays change configuration of
strings throughout day, and throughout year, to maximize solar
harvest... For example early morning or late afternoon, or cloudy day, then 6 strings with 2 panels each might be better. While midday, with clear sky and cold temperatures, 1 string with 12 panels might be better. Colder temperatures are better because cold lowers resistance. |
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| Read
more about Ohms/ resistance in solar Please read following: Solar power curve charts Convert AC water heater to DC DC arc extinction .pdf |
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DC arc
extinction/ controlling high voltage DC "the higher the number of contacts opening the circuit, the higher the breaking capacity of the circuit-breaker. This means that, when the voltage rises, it is necessary to increase the number of current interruptions in series, so that a rise in the arc voltage is obtained and consequently a number of poles for breaking operation suitable to the fault level." What this quote means: A DC circuit breaker or any DC switchgear must have multiple contacts that disconnect as illustrated in diagrams below You want to increase the number of contact points, so the arc from DC power can be extinguished Resources: DC arc extinction .pdf Read about difference between AC and DC |
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Switchgear for DC: Extinguish arc using contacts in series AC contactor can have longer life-expectancy when switching DC if wired as shown,. This puts 4 sets of contacts on the positive wire. Obviously if all four contacts are disengaged at same moment, it will be more difficult for DC to arc across all four. Or use a 3-pole for better arc extinguish using six contact points Or use 4-pole contactor and 3 poles (six contact points) are used for positive wire, and 4th pole (2 contact points) is used on negative wire. As we can see from this example, DC electrons flow from positive to negative because we are trying to extinguish the arc on the positive wire. Resources: 3-pole contactors Difference between AC and DC |
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Convert
AC water heater to DC Resources: Convert AC water heater to DC All solar resources |
  Fuseholder Fuse |
Photovoltaic
fuseholder/ DC fuseholder/ 1000 volts DC/
DC fuse/ photovoltaic fuse: use 20-25 amp fast-acting for designs on this page Not waterproof... mount inside Nema 3R enclosure >Mount on din rail/ change fuse with flick of finger Install 25-30 amp fuses Use 10 x 38 DC fuses Buy: Photovoltaic fuseholder / DC fuseholder/ ultrasafe/ at Amazon Ultrasafe fuseholders at Amazon 600 volt DC fuses at Amazon Mersen 600 volt DC fuse |
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Waterproof
Solar fuseholder/ 1000 VDC/ 2 amp to 30 amp Buy Solar fuseholder at Amazon Fuse holder plus 20 amp DC fuse Fuse holder plus 30 amp DC fuse |
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DC
circuit breakers for Solar/ use 20-25 amp for designs on this page Buy from my affiliate links: DC circuit breakers High voltage DC circuit breakers at Amazon Combiner boxes at Amazon Resource: How to set up solar array |
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Din
rail for mounting Breakers, fuse-holders, timers, relays Make your own breaker box, combiner box Buy: Din rails for mounting Combiner boxes at Amazon Resource: How to set up solar array |
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Solar
power books Learn the basics with tips and help for professional and beginner alike Buy from my affiliate links: Solar power books |
Clean solar panels are ≈9% more efficientArray that is cleaned regularly will harvest more solar power. Measured experiments between clean and dirty array shows: The clean array's power output increased by 9% over the dusty array. This experiment was done on clear solar day with 'direct overhead' sun and panels were coated with nature-applied environmental dust, smoke etc in Utah. Ordinary city-water hose was used to clean array. Other factors of exact science were assumed to be equal or ignored. Solar mounted on pole My friend Network writes: I try to extract as much as I can out of each day. If I don't hurt by evening I'm doing something wrong. Top of pole. 3 panels per string. 245W mono. Mr Long Arm Longest model product placement. Throw in 1/2 moon for free. Schedule 40 galvanized pipe 6-5/8 OD. 10 footer. Factory end on top. 4 feet into the dirt with cement. That sucker ain't going anywhere. Top of poles are easily to spin. Ground mounts are not. I also countersunk dents in the pipe for the bolts (E-SE-S-SW-W). See pic. Then I made some handles so I can easily change position instead of using a wrench on the bolts. I turn them to the West in the summer when I need cooling. South in winter to max the yield. I could easily manually track the sun during the day if I wanted to. I can adjust the angle as well but I never do. Its way more effort than spinning. |
Multimeter Test for breaks in wire/ Test for voltage Most appliance require 80% rated voltage to function correctly Buy Analog multimeter Multimeters at Amazon Klein multimeter Electric testers at Amazon Clampmeter for testing amp flow on line Resource: How to test and replace element How to test thermocouple Element tests for 120 volts How to test wire |
Safety
when testing wires:
Never touch wet or previously flooded appliance. Never stand on wet surface when working on electric. Never stand on bare soil, put down dry boards. Tape tester leads to wood sticks to keep hands away from power. Use non-contact voltage tester before touching wires. Never touch or lean into any made of metal. Remove metal objects from pockets. Do not use oxygen or fuel accelerants in same room as electrical repairs Resource: Basic house wiring |
 Non-contact voltage tester Test for power without touching connectors NEVER assume power is OFF Buy: Non-contact voltage tester Amazon Electric testers at Amazon Resource: How to test electric power is off |
 120 volt 15 amp devices
including GFCI, timers, switches, plugs, wifi controls etc can be
installed on 15 or 20
amp
breaker.120 volt GFCI, outlet, receptacle that is rated 20 amp can be installed on 20 amp breaker only, but NOT on 15 amp breaker. Buy 15 amp GFCI 20 amp GFCI |
Buy Basic electric book Home plumbing/ electrical codes  Or learn about basic household electricity... use and search my site/ Resource Safe electric wiring Basic house wiring |
 Use outlet tester to check for correct wiring on any 120 volt straight-blade outlet. Buy: Klein testers Outlet tester Circuit breaker finder Electric usage monitor |
Twist-on wire connector assortmentsDo not reuse old connectorsTwist wire connector very tight. Pull wires to ensure they will not come loose. Cover all bare copper. Buy: Connector assortment at Amazon Connector assortment at Amazon Resource How to select and install twist-on wire connectors |
Weatherproof wire connectorConnector cavity is full of siliconeBuilt-in cover keeps silicone in place Protect from water, dust etc Buy from my affiliate links Weatherproof size 14 to 6 Amazon Weatherproof size 22 to 8 Amazon Resource How to select and install connectors |
Connect wire to screw terminal Use only 600 volt solid copper wire. Do not use stranded wire or extension cord. Do not use solder anywhere on residential 120-240 volt wiring. Attach electric installation to structure. Tighten screws very tight against wire.  Buy: NEC books Dewalt plumbing/ electrical codes Basic electric book National electric code guide/ illustrated Resources: How to twist wire How to select and install twist-on wire connectors |
 Weatherproof
lever switch on outdoor lightsSafely operate outdoor toggle switch Replaces outdoor cover Install over top of ordinary switch Works with single-pole, double-pole, 3PST, 3-way, 4-way switches etc Use weatherproof box for outdoor Can be used indoor or outdoor Buy: Best choice: Cantex lever switch Outdoor lever switches at Amazon Lever switches Resource Cantex-toggle-switch-covers.pdf Cantex-PVC-junction-boxes.pdf |
Buy: |
Push-on wire connectors in place of twist-on connectorsBuy:Push on wire connectors Amazon Red 3P connector for 10-14 gauge wire Lever connectors for stranded wire at Amazon |
Use nipper instead of pliers or screwdriver for removing staples (and nails). Do not damage cable or wires inside cable. Code -Cable SHALL BE secured without damage to the outer covering. NEC sec. 336-15 Buy End cutting nippers at Amazon |
 When removing insulation from wire, do NOT score or put cuts on surface of copper wire. Doing so increases resistances on wire and creates weak point. Buy tools: Wire strippers at Amazon Linesman pliers Pro linesman plier Needle nose pliers End cutting nippers at Amazon |
 Weather resistant plastic box for outdoor extension cord connections, Christmas lights, outdoor power strip etc . Not for connecting wires with wire nutsŪ, or in-wall wiring, but can be used indoors to organize extension cords, power strips etc. Weather resistant is not weatherproof or watertight. Use enclosures rated IP65 and IP67 for waterproof. Extension cords cannot be used for permanent wiring. Buy: Large-medium-small electric cord box Socketbox Raintight enclosures Water-tight cord lock Resource: Enclosures and boxes |
 Contactors/ relays |
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