The document discusses electrical connectors used in solar photovoltaic systems. It describes connectors as electro-mechanical devices that join electrical terminations and create circuits. It outlines the key properties of connectors, including their physical construction, size, contact resistance, insulation, and durability. It also explains the important role connectors play in connecting solar panels together in strings and to inverters. The document recommends standards for plug connectors to ensure reliable connections between components from different manufacturers.

1. CONNECTORS IN SOLAR
PHOTOVOLTAIC SYSTEM
Made by : Nikunj J. Usadadia
(17MSE009)
PANDIT DEENDAYAL PETROLEUM
UNIVERSITY

2. CONTENTS
 Electrical connectors
 Properties of electrical connectors
 Connector’s role on a solar project
 Managing solar connectors: A report by
MNRE
 IEC connectors
 Acknowledgements

3. ELECTRICAL CONNECTORS
 Electro-mechanical devices
 Used to join electrical terminations
 Creation of electrical circuits
 Consists of plugs (male-ended) and jacks
(female-ended)

4.  Connection may be temporary or permanent
electrical joint as per requirement
 Adapter can be used to bring together two
dissimilar connectors
 Manufactured for power, signal and control
applications
 May join two lengths of flexible cable or
connect a cable to an electrical terminal

5. PROPERTIES OF ELECTRICAL
CONNECTORS
Electrical connectors are characterized by:
• Their pin out and physical construction,
• size, contact resistance,
• insulation between pins,
• ruggedness and resistance to vibration,
• resistance to entry of water or other
contaminants,

6. • resistance to pressure, reliability,
• lifetime (number of connect/disconnect
operations before failure),
• and ease of connecting and disconnecting.
 KEYING
• with some mechanical component which
prevents mating except with a correctly
oriented matching connector.

7. • can be used to prevent incorrect or damaging
interconnections,
• either preventing pins from being damaged
by being jammed in at the wrong angle or
fitting into imperfectly fitting plugs,
• or to prevent damaging connections, such as
plugging an audio cable into a power outlet.

8.  LOCKING MECHANISMS
• To prevent inadvertent disconnection or
poor environmental sealing.
• Locking mechanism designs include locking
levers of various sorts, screw locking, and
toggle or bayonet locking.
• Depending on application requirements,
locking mechanisms may be tested under
various environmental simulations that
include physical shock and vibration, water
spray, dust, etc. to ensure the integrity of the
electrical connection and housing seals.

9. CONNECTOR’S ROLE ON A SOLAR
PROJECT
 A solar array is all about connections—panels
need to be connected to each other, and to
inverters.
 Connectors attach solar components
together to produce a successful flow of
electricity.

10.  On DC-based projects, panels must be
connected into strings.
 Usually the connectors are installed on the
panels at the factory, but they can be field-
installed.
 End-panels have to then be connected to an
inverter or combiner box, and those
connections are often done in the field.
 On AC/micro inverter projects, connections
are made between the panel and the micro
inverter.

11.  These connections are usually pre-installed
with cabling, especially on plug-and-play
integrated solar modules.
 Beyond their role in aiding electrical
connections in PV solar arrays, connectors
must meet the voltage and current
requirements for their service while
providing a low resistance point of contact.
 They also must endure temperature extreme
and thermal cycling, resist mechanical
events and prevent disconnection for
lifetime of the array.

13.  They require adequate engineering
consideration to meet the requirements of a
project.
 In addition to surviving extreme swings in
outside temperatures, direct sun, snow and
rain, connectors have to support increasing
voltages.
 One of the biggest issues that prevents
connectors from moving electricity from
Point A to Point B is that not all of them mate
together nicely.

15.  For DC systems, commonly a ‘MC4 connector’
is used. The MC4 design is a specific
manufacturer which does not recommend
mating with connectors of different
manufacturers.
 The lack of an industry standard means that
compatibly of the connection cannot be
assured, especially over the 20- to 30-year
lifetime of the array.
 Proper training is also a must when it comes
to handling connectors, even though the act
of connecting solar components together
seems easy.

16.  Connectors are one of the final pieces to a
solar puzzle, and they’re just as important as
the panels themselves.
 These small components shouldn’t be ignored;
they’re essential to a successful project.

17. MANAGING SOLAR CONNECTORS: A
REPORT BY MNRE
 Prepared by ministry of new and renewable
energy, India for safety and longevity of PV
system.
 Need: Inadequate contacting can cause
electric arcs.
 The contacts must also show permanently
low contact resistance.

18.  Screw terminals and spring clamp connectors
(e.g. in the module junction boxes and for
connection to the inverter) are gradually
being replaced by special, shock-proof plug
connectors, which simplify connection
between modules and string cables.

19.  Plug connectors and sockets with welded cables
are also available in the market.
 STANDARDS FOR PLUG CONNECTORS
 Since PV modules generally come equipped with
preassembled plug connectors, several modules
can easily be connected to form a string.
 A variety of different cable connectors are
available in the market, and as yet no standards
have been established for these interconnection
systems.

20.  Plug connectors from different manufacturers
are usually either completely incompatible or
they fail to provide a connection that will
remain permanently snug.
 If the connector fits too tightly, this can cause
the insulating plastic parts to break. A loose
fit, on the other hand, poses the risk of
creating high-contact resistance.
 This leads to yield losses and the areas
around the connection heating up, even
causing an electric arc and the connector to
melt.

21.  A standard for photovoltaic plug connectors,
which should be as international and uniform
as possible is desirable and necessary to
ensure reliable connections between
products from different manufacturers.
 If such a standard were to be introduced,
manufacturers would be in a position to offer
reciprocal warranties for specific cross-over
connections.

22. IEC CONNECTORS
 An IEC connector refers to a type of electronic
cable that meets the International Electro
technical Commission (IEC) standards.
 The specification for IEC connectors is IEC-
60320.

23.  The connectors mount with cables are
commonly referred to as female connectors
or sockets, whereas the connectors mount
with panels are known as male connectors or
plugs.
 In the classification of IEC connectors, odd
numbers denote the female connectors. The
corresponding male connector number is the
number of female connectors plus one.
 Thus, C1 is female connector and C2 is the
matching male connector. The set of thirteen
such male and female connectors are
possible.

24.  Example of male and female connectors is
such as:
• C1 and C2: These connectors have 2
conductors, a rated current of 0.2 ampere
and a maximum temperature of 70°C.
 More details about IEC connectors can be
obtained from:
http://www.farnell.com/datasheets/311707
.pdf

25. ACKNOWLEDGEMENTS
 Kelly Pickerel
 Ministry of new and renewable energy, India
 Khyati Vyas
 Chemtrols Solar Private Ltd.
 Techopedia

26. THANK YOU