I've got Spaghetti- any Wire Management & Tying tips??

[Syberdog]

What a headache... I originally though 'just coil the wires and tie them then run thru the rail clips' no big deal... Wrong!
I found out that PV wire doesn't bend easily and the connectors need a unlock tool so better have it aligned without kinks, crosses and the way you want it before tieing it up. Which brings up the chicken/egg question... does one tie and hang the wires before or after connecting the panels?
Any tips or advice on hanging this plate of spaghetti would be appreciated.








Thanks
sd

[bcroe]

Looks like a wire management problem, in an otherwise super neat construction. Do I see optimizers?
There are a few ways to organize wires; you might need a cable rack. One way is to run a series string
to every other panel to use up the length, doubling back to connect the other panels. Another is to
turn some panels around to use up length. Worst case cut and crimp on new MC4s. My wires pretty
much run along the supports, winding around them to use up excess length. The best arrangement
might turn out to need an MC4 extension cord somewhere, easy to make esp if there are scraps from
trimming. Don't cut anything really short. good luck, Bruce Roe

[Syberdog]

Orienting the panels so the wire was all in one line seemed like a good idea at the time....
Is it anti-code to wrap the cable around the rails to take up length? I don't plan on remounting any panels or cutting any wire- I might be able to put wire clips on a higher rail and run between to two...

[littleharbor]

[QUOTE=bcroe;n366157]One way is to run a series string
to every other panel to use up the length, doubling back to connect the other panels.
Bruce Roe[/QUOTE}


Here's a diagram for leap frog wiring.
Leapfrog wiring of series wired panels.jpg

Not sure how the cables will work out with microinverters/optimizers though.

[Syberdog]

I tried to leapfrog but the optimizer wires are about 3" too short so I decided to work one noodle at a time. Starting with the optimizer cables I came up with two possibilities... which one do y'all think better? ... or ??? (after tied, I will add some zip ties to the cable, rails or frames to help further lift or secure in place)


option 1


option 2

BTW, Are the optimizers supposed to remain unconnected until the panels are connected up first? I can't connect the panels until I have their wire coiled and secured or else it becomes difficult if a coil has to be redone different....

[littleharbor]

Looking at your earlier pictures, I think after all is wired up you could easily enclose that area between the 2nd and 3rd rail and have all wiring out of sight. It would really clean up the mass of wiring and take it out of sight and reach of uninvited hands.

[DanS26]

Whatever you do......do not have your connectors in a drip zone. Also if possible have the connector the highest point of the loop.

[bcroe]

I tried to leapfrog but the optimizer wires are about 3" too short

That sounds very close. How about, mount each optimizer moved 3" from the next one, so
they just reach?

Half the panels here have been relocated; would much rather do that, than crimp on new
connectors. Might be easier here with each panel individually bolted, instead of held by
overlapping clamps. Bruce Roe

[Syberdog]

Looking at your earlier pictures, I think after all is wired up you could easily enclose that area between the 2nd and 3rd rail and have all wiring out of sight. It would really clean up the mass of wiring and take it out of sight and reach of uninvited hands.

My wife likes that idea too, Now to figure out exactly how to do it. Maybe use the bottom channel of the rails and a flexible sheet material or grill/screening. I'm open for suggestions.

It ain't pretty but its done and all the connectors are plugged- I better order a disconnect tool. Too dark for pics but you would scream if you saw it anyway.

[GRickard]

You could try something like a Panduit finger trough. It's made for wire management.

Greg

[AzRoute66]

I really like the idea of leap frog, however, if we were short 3" on equidistant optimizers, bringing one in those 3" will leave the next run 6" short, etc. and sooner or later it is going to catch up to you. I think we could have got away with it as we only had to 'short' a maximum of five panels (5x3"=15"). (Both strings start and end in the middle).

It would be a big undertaking to lift all of those panels just to make such a move, and you would need more clamp star washers (Weeb washers?) as they are supposed to be single use only. So, 'leapfrogging' definitely appreciated now that we've seen the method. This is one of the reasons I was so eager to go out and assist - lots of little things you won't get unless you are smart/experienced enough to ask (which I'm not). Heck, the neatest thing I learned was that the 'indent' mark on the clamp bolts will tell you when the diamond head of the clamp bolt is properly positioned in the rack channel...

It was a great experience putting up that array with Syberdog, and I'm grateful he provided me with the opportunity. When he puts up the next one, I'm going to get out there early enough to play in the concrete.

[littleharbor]

I was thinking sheet aluminum, by the roll, comes in different widths and gauges. Attach it with Stainless self tapping screws.

[bcroe]

I really like the idea of leap frog, however, if we were short 3" on equidistant optimizers, bringing one in those 3" will leave the next run 6" short, etc. and sooner or later it is going to catch up to you. I think we could have got away with it as we only had to 'short' a maximum of five panels (5x3"=15"). (Both strings start and end in the middle).

It would be a big undertaking to lift all of those panels just to make such a move, and you would need more clamp star washers (Weeb washers?) as they are supposed to be single use only. So, 'leapfrogging' definitely appreciated now that we've seen the method. This is one of the reasons I was so eager to go out and assist - lots of little things you won't get unless you are smart/experienced enough to ask (which I'm not). Heck, the neatest thing I learned was that the 'indent' mark on the clamp bolts will tell you when the diamond head of the clamp bolt is properly positioned in the rack channel...

It was a great experience putting up that array with Syberdog, and I'm grateful he provided me with the opportunity. When he puts up the next one, I'm going to get out there early enough to play in the concrete.

Just move each optimizer over an ADDITIONAL 3" till you run out of whatever, then slip in a short
extension cord and start again. Not having optimizers, I didn't realize you need to lift the panel to
move its optimizer. My bolts aren't single use, only the fuses and Weeb washers are. Bruce Roe

[AzRoute66]

You could try something like a Panduit finger trough. It's made for wire management. Greg

Panduit would be perfect for this situation if it were UV/weather resistant, about 1/6th of the current price (and preferably in matte black ). I've been researching the 'back of array' wire management issue, and it appears that it is a pretty considerable problem. I think I'm going to get a lawn chair and park it behind that array and cipher on a solution. There are NEC issues too (of course).

[NukeEngineer]

+1 on leapfrog! I did this with all four strings on my array. Most of my strings were boring (one panel next to the other), with some gaps, one of which was the size of a whole panel.

However, my last string was an odd 3x3 + 1 square, and I was able to leapfrog this one as well. I had to stare at it and figure out where to go next, as I was wiring this one, but it worked out. See attachment. Yellow lines indicate how these optimizers got connected together.