INSTALLER INSIGHTS Chuck Heath c. 1993 Chuck Heath These tips are not in any particular older. Your additions to this list are always welcome. By sharing we will all do a better job. 1. SCREW installation in cramped spaces is made easy by coating the screwdriver tip with office-supply glue-stick. It's water soluble too 2. HONDA generator remote-control units can be extended at least 300 ft. using 10 conductor, #18 gauge Sprinkler Control Cable. It is direct-burial (waterproof). The remaining conductors can be used for a remote amp-hour meter. 3. SHIELDED twisted pair cable, #18 gauge, is available from Carol Wire. 4. SQUARE D brand 70 Ampere load centers can be ordered with oversized main lugs (up to 1/0, I believe) for those long DC runs. 5. 24 VOLT ARRAY WIRING is much simpler wiring one-half as 12 Volts then combining the other half 12 Volt side just once in series. 6. LONG CONDUIT PULLS with heavy wire can be simplified by dry-fitting every 40 feet and all sweeps (bends). Be sure to mark the dry-fit locations (marking pen, colored tape) to be glued after the wire pull is complete. 7. THIN-LITE DC light fixtures that are creating RFI (radio frequency interference) can be quieted with a mylar capacitor available from the manufacturer who still refuses to install them at the factory. 8. GFCI (Ground Fault Circuit Interrupter) are about a 2-watt phantom load. Too many will "wake-up" a "sleeping" inverter. For the cost of about 5 GFCIs, you can install a GFCI breaker in the AC circuit breaker panel to reduce the number of GFCI loads. 9. PVC pipe in trenches (water or electrical conduit) can be cut with nylon string in places you cannot use a hacksaw. 10. If you suspect a problem with DIP SWITCHES, try exercising each one several times to break the conformal coating for better electrical contact. 11. LIQUID LEVEL CONTROLS for 12 and 24 VDC are available from Warrick Controls, Inc., 4237 Normandy Court, Royal Oak, MI 48073 (313) 545-2512. These are frequently used in water storage tanks to control a well-pump using small-gauge wire. The storage tank and pump can be up to 2 miles apart. 12. CALCIUM SCALE in home water systems can be largely eliminated with a magnetic descaling unit which draws only 3 watts and runs on 12 VDC or 120 VAC. No maintenance, it is all electronic. The unit I have is called ScaleWatcher and is about $400. It works! 13. LIGHTNING DAMAGE can be reduced by forming a loop in wiring, coaxial cables, etc. and leaving the down feed at right angles from the tower, pipe, mast or PV array. One of the best sources for lightning solutions is PolyPhaser Corporation, POB 9000, Minden, NV 89423 (800) 325-7170. Their product line covers everything from twisted pair/cable protectors to satellite dishes. 14. PV ARRAY interconnect wiring using Tray Cable (designated type TC) is often less expensive than USE or SO type cable. TC is UL-listed direct-burial (waterproof) and UV resistant. I use TC 10-2 stranded for arrays up to 25 Amps output. 15. HOT WATER TANKS to make a solar batch-type unit can often be obtained free from your local propane supplier or plumbing house. Usually they are electric models traded in on propane tanks. 16. BATTERY EQUALIZATION should be done after disconnecting all DC loads and removing Hydrocaps, if you have them. 17. CELLULAR TELEPHONES range can be greatly extended using an 800 mHz. Yagi antenna and low-loss feedline. My neighbor does this successfully over an 83 mile path (from his home)! 18. A SECONDARY SURGE ARRESTER that looks like a ac power & cube and fits a standard 1/2 inch electrical knockout is offered by Square D Company. Can be used on 3 wire 120/240 Vac load centers or 2 wire 120 Vac. It's their #SP1175. 19. EMI/RFI INTERFERENCE from inverters may be reduced by a line filter rated at 120/240 Vac, 30 Amperes available through Trace Engineering. A cheaper solution from Richard Perez of Home Power Magazine is to twist both the DC input and AC output cables during installation. Make the cables about one- third longer before twisting as the overall length shrinks during twisting. 20. OWNING YOUR OWN PROPANE TANK allows you to shop for the best price but beware, used butane tanks are only rated at 125 psi. Propane tanks are rated 250 psi. NEVER put propane in a butane tank! I'm saving about 1/3rd by owning rather than renting from the supplier. Check the tank label. 21. SERVEL REFRIGERATOR parts including new burner assemblies and door seals are available from Jeff's Gas Appliances, 549 Central St., Willits, CA 95490 (707) 459-5223. Wholesale and retail. 22. Always draw a block diagram/schematic of your ELECTRIC SYSTEM. Someday, it will require trouble-shooting by you or someone else. Color code, label, detail every connection. See Home Power Magazine for good examples. Post system- shutdown instructions. Someone else may have to shut it down quickly. 23. BATTERY BOXES can be made from old, discarded, chest-type freezers, placed outside the home. Extra insulation can be added in cold climates. I put 2 - 6 x 6 timbers across the bottom covered with scrap 2 x 6 boards for better access Ventilate at the top. Seal the electrical conduit into the house to prevent any hydrogen entering (canned foam insulation). Check your appliance dealer for a free, gutted unit. 24. BATTERY WATERING is greatly simplified by using a special jug available at auto parts stores. The spring-loaded valve opens when you press it down into the cell. Remove it when the water no longer flows. Under $10. No funnels anymore. Please do add your own suggestions, corrections and better ideas to this list. Access Author: Chuck Heath, Suntricity, POB 1159, Coulterville, CA 95311 ù 209-962-7012 ù 209-878-3557