WILEY

Results: (as of 2/23/07)

After seeing no adverse affects from the other two tests we decided to take our testing to the next level and subjected our WEEB to repeated cycles of a 105°C salt water bath(~8hrs) followed by an oxidation period(~16hrs). After more than 131 cycles, the WEEB has shown no distinct change in continuity or perfomance! Unbelievable! If you can think of a harsher/more destructive test we'd like to hear about it. Continuity of the WEEB connection was evaluated by measuring resistance from solar panel frame to rail, through the WEEB. The average resistance measured has remained constant and is about 2 mΩ.

The top-left photo shows the the entire test assembly encrusted in salt after a 24 hour test period. The bottom-left photo shows a close-up of the control, which consists of an anodized piece of aluminum mounted directly to Unirac rail using zinc-plated steel hardware (nut and washer). The severe corrosion exhibited by the steel hardware is convincing evidence of the extremely corrosive environment that is used for testing the WEEB.

As a result of this testing we found that simply scraping off the oxide coating from both anodized alumninum surfaces provides the same reliable connection achieved with the WEEB. So, why use the WEEB at all? The time saved and the consistent results achieved by using the WEEB are far superior to scraping the anodized coating off each rail and panel.

 

 

 

We also ran these tests using an Ilsco lug mounted with the recommended stainless steel screw engaging two threads on the side of a rail. The problem here is that when you drill a hole, you remove anodizing and leave a site at which corrosion begins. The lug fell out of the rail after 95 cycles, as shown in the picture at left. NOT RECOMMENDED FOR COASTAL INSTALLATIONS!

The Test:

1. One pair of solar panel frames were attached to a rail using 2 WEEBs.
2. One WEEBlug was attached to the rail with a 6 AWG wire inserted into the lay-in portion of the Lug.
3. One piece of anodized aluminum was attached to the same rail (for comparison).
   • Anodized coating on both rail and aluminum piece was scraped off before assembly.
4. The entire setup was subjected to repeated cycles of:
   • salt water bath: saturated salt water solution @ 105°C (~8 hrs)
   • oxidation period (~16 hrs)
5. Resistance was measured for..
   • WEEBs: from solar panel frame to rail, through the WEEB
   • WEEBlug: from lug-body to rail, and from 6 AWG wire to rail
   • Piece of Aluminum: from top of aluminum piece to rail