Solar install turning out really bad - looking for some help/advice please.

[HX_Guy]

WTF does the conduit size have to do with anything.... as long as the correct sized conductors can fit inside??

That's not true. It has to do will fill calculations and heat. NEC code addresses this and says that conduit can't be filled more than 40% if I remember correctly because the cables can overheat if they don't have "room to breathe".

[J.P.M.]

That's not true. It has to do will fill calculations and heat. NEC code addresses this and says that conduit can't be filled more than 40% if I remember correctly because the cables can overheat if they don't have "room to breathe".

It's a situation dealing with heat transfer. Stuff too much heat generating wire into a conduit and a larger area is required (a bigger conduit diameter) to dissipate the heat and thus avoid overheating due to inadequate heat transfer surface area. NEC rules are probably conservative for most conditions if followed.

[Alisobob]

If the wire is getting hot.. you have the wrong sized wire....

Common Sense 101

[J.P.M.]

If the wire is getting hot.. you have the wrong sized wire....

Common Sense 101

That's one cause. Other parts of the NEC code probably speak to that issue. There are other reasons or temp. increases.

If I stuff twice as much properly sized wire in a conduit, all other things being equal, the additional wire will generate something like twice as much heat inside the conduit, but the wire won't be twice as hot from resistance heating. The conduit will however, need something like twice as much outside surface area to dissipate twice as much heat from twice as much wire through a combination of conduction, convection and radiation heat transfer mechanisms.

In the case of twice as much wire = twice as much heat generation, the temp. increase inside the conduit is due to inadequate heat transfer to the surroundings and therefore heat retention and temp. buildup inside the conduit, including all the contents. Like I wrote, its a heat transfer situation.

Common sense is great, sometimes it's not straight forward. In this case, it probably ain't enough without a little critical thinking to go with it.

[HX_Guy]

Just talked to the inspector, we're the first stop and she should be here within an hour. Come on baby, maybe 3rd time's a charm?

[Jason]

Good Luck HX Guy, its been a long road, hopefully today will be a a win for you, cheers.

[SunEagle]

Just talked to the inspector, we're the first stop and she should be here within an hour. Come on baby, maybe 3rd time's a charm?

Looking good HX_Guy. I have got my fingers crossed for a Pass Inspection result.

[HX_Guy]

Showtime!

[HX_Guy]

Halle-freaking-lujah!!!

[Amy@altE]

HOLY COW!!!! YOU DID IT!

[Alisobob]

Get a photo of Bigfoot... a UFO.... and the Cubs winning the World Series... and you have the whole set.

Congrats...

[Ben25]

Awesome!!!

[HX_Guy]

Thanks guys, and thanks everyone for your help throughout this!

[Living Large]

NOW it is time for the Dance of Joy. Anyone can design a system - it's building it that counts. Congrats.

[SunEagle]

Congratulations. Looks like your hard work paid off.

Interesting the inspection sticker states that some parts of the project were "not inspected" and therefor compliance is the responsibility of the Contractor who maybe by now is "in the wind".