PV DC connections in
single-axis tracker applications

APPLICATION PRACTICES

Integrating PV DC connectors into single-axis tracker applications

Solar single-axis tracker systems efficiently help to optimize the capture of solar energy by automatically adjusting the orientation of photovoltaic panels throughout the day.

Unlike fixed solar panels, single-axis trackers pivot around a single axis,to follow the sun's path from east to west. This dynamic adjustment increases the efficiency and energy output of solar installations. Single-axis tracker systems are widely used in large-scale solar farms and utility-scale PV plants where maximizing energy production is crucial, especially in areas with high solar irradiance.

What to consider for the integration of PV DC connectors into single-axis tracker systems

The PV DC connectors are the key components transmitting the harvested solar power. They are responsible to establish a reliable, safe and long-lasting performance of the solar power plant.

The dynamic adjustment of the single-axis tracker system is challenging the PV DC connector installation. These movements create mechanical stress on the connecting parts, like wires and connectors. Therefore, a couple of provisions are to be considered for such areas of application.

The challenges and solutions

Application

 

Where to specifically look at:

  • Primarily at the end of row and/or in between tracker tables.
  • Low-stranded conductors with limited flexibility

Challenge

 

Mechanical load creates stress on the connection solutions:

  • Inadequately secured connectors may be exposed to cyclical mechanical loading and movements, that could induce fretting or excessive contact surface wear. This could lead to a shortened life expectancy and premature failure, imposing significant risks to PV assets.
  • PV connectors should be protected from dynamic movement and mechanical stress, such as those caused by moving components of a PV tracker system by utilizing proper wire management installation techniques.

Any such relative movement may lead to an accelerated deterioration of the electrical contact itself, generating more heat, therefore causing higher temperatures and possibly reducing the life expectancy of the connector. Larger and stiffer wire, as often used in eBOS applications for high-powered PV modules, are more susceptible to inducing such relative movement than smaller and more flexible wire.

Solution

 

Follow all instructions of the assembly instruction and pay particular attention to the following:

Mechanical Isolation of Connector
When integrating a PV connector into an application where mechanical load is expected, assure the connector is appropriately secured and decoupled from both static and dynamic mechanical loads (for example: strain, bending load, torsion, and translational movement).

Connector placement
Place connectors in areas where no mechanical movement occurs. For example, do not install unsecured connectors between the DC collection and end of row so that the connectors hang freely as part of a dynamically moving cabling section.

Choose Flexible Conductors
Make use of high-flexible (highly flexible or high flexibility - unless “high-flexible” is a term of art) PV conductors in areas of constant movement (typically end of row and in between tracker tables). Be sure to follow the specific assembly and installation instructions and guidelines for such conductors.

Best practices
Follow best practices for wire management and connector system integration as explained in the assembly instructions provided with the PV connectors, as well as in system integration advisories, product guides, and all other product information.

 

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The strain relief measures described in the installation instructions aim to mechanically decouple the electrical contact from any possible static or dynamic load caused and induced by the installation or external factors, to prevent relative movement of the electrical contact.

Examples of how to properly secure PV connectors

The illustrations provide some best practice samples of how to properly secure PV connectors by isolating them from mechanical movement induced by the tracker system.

It is essential to verify the correct integration of the PV connector within the PV system during its final application (i.e. in its end-use)

Examples of securement methods at the torque tube 

Examples of securement methods at the connection to the combiner box

Examples of securement methods at the connection to the combiner box

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