Study Reveals Top Causes of Rooftop PV System Failures
A study by the U.S. Department of Energy's Sandia National Laboratories has shed light on the most common causes of failure in rooftop photovoltaic (PV) systems. The analysis, published in Solar Energy, examined 6,276 connectors from 265 individual rooftop systems across seven U.S. regions.
The research, conducted between 2014 and 2020, found that tight wire bending radius (2.2%) and extra dirty connectors (1.3%) were among the top causes of failure. Loose nuts also contributed significantly, with a critical failure rate of 41% for fiber optic connectors. High current levels were linked to connectors' higher resistance ranges and critical failure rates due to resistive heating.
The study also highlighted that connector types designed to limit heat dissipation often had higher failure rates. Additionally, rounded contact barbs in some connectors could lead to retainer failures. A performance assessment of cross-mated connector models showed varied results, with some performing adequately and others not.
The analysis, which involved barcoding, wire stripping, visual inspection, 4-wire resistance measurements, and X-ray imaging, aims to increase publicly available data on connector failures. Understanding these common failure causes can help improve PV system reliability and longevity.
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