Quality and Safety in Photovoltaics: Why It Matters and How to Measure It

Solar power is now the least costly option for new electricity generation in most countries worldwide. As the global weighted average cost of electricity from solar PV continues to decline, it remains at the forefront of the energy transition. However, as asset owners and operators face pressure to reduce Capital Expenditure (CAPEX), the temptation to use cheaper, low quality components grows. This raises a critical question: does sacrificing quality on small components jeopardize the overall performance, safety, and financial viability of a solar plant?

In a recent roundtable, experts from Stäubli Renewable Energy, a player in the PV industry for nearly 30 years, shared their insights on this crucial topic.

The Hidden Risk: Why Small Components Have a Big Impact

While PV connectors are small, they represent a significant point of failure in solar installations. Recent data reveals a startling trend:

• 74% of all problems in a PV system occur in the DC distribution.
• Within that DC sub system, a staggering 59% of all issues are related to field-made connectors and poor wire management.

The consequences of using low quality connectors or improper installation are severe. Before a connector fails completely, its contact resistance increases, leading to performance degradation and power loss. This forces operators to spend time and money identifying and replacing the faulty connection, all while losing revenue due to the plants reduced performance. These issues negatively impact the plants return on investment and the overall Levelized Cost of Energy (LCOE).

The Danger of the Mix: Why Cross-Mating Connectors is a Critical Error

One of the most common and dangerous issues seen in the field is the cross-mating of PV connectors from different manufacturers. Mating connectors that are not from the same product family can create dangerous situations due to incompatibilities in internal contact technology and materials.

The standards are clear on this point. The National Electrical Code (NEC) explicitly states: Where mating connectors are not of the identical type and brand, they shall be listed and identified for intermateability, as described in the manufacturers instructions.. However, a critical fact remains: to date, no connector has been listed as intermateable with the Original Stäubli MC4. Field inspections consistently confirm that cross-mated connectors are a common source of problems.

The Path to Reliability: Quality Products and Proper Installation

The solution to preventing these costly and dangerous failures is twofold: choosing high-quality, certified products and ensuring they are installed correctly.

• Choosing Quality Products: When selecting connectors, critical factors include the manufacturers credibility and the quality of their products, which can be determined by the materials used and proven through rigorous testing. Operators should look for components that have been independently tested and certified by official bodies like TÜV Rheinland or UL against established standards such as IEC 62852 or UL 6703. These certifications serve as a foundation for the long term reliable operation of a PV plant.
• Ensuring Proper Installation: However, having high quality products alone is not sufficient to enhance safety. It is equally important to know how to properly assemble PV connectors and integrate them into the system. Most issues in the field arise not only from low quality parts but also from improper handling and assembly due to a lack of knowledge.

Building Expertise: The Role of Training and Certification

To address this critical knowledge gap, Stäubli is dedicated to sharing its expertise through training and on site services. The Stäubli Customer Academy provides specialized courses designed to enhance the knowledge of EPCs, installers, and other stakeholders. These courses focus on PV connector configuration, assembly techniques, and a comprehensive range of installation guidance. Installers who successfully complete these training programs can receive certification, giving asset owners confidence in the quality of the assembly.

By combining certified, high quality components with correct installation by trained professionals, solar plant operators can prevent costly issues, ensure long-term stable performance, and protect their return on investment.

Learn more about Stäubli's commitment to quality and safety in renewable energy: www.staubli-renewable-energy.com