HelioVolta has released “PV Connectors: The State of the Field,” a new report that highlights the persistent risks of low-cost PV system components, specifically connectors, to solar investments. The white paper details observations from over 5 GW of independent field inspections conducted by HelioVolta at hundreds of utility and commercial solar projects in the United States.
For years, industry professionals have known that improperly made connectors introduce significant safety risks to PV systems. Since 2008, successive revisions to the National Electrical Code have aimed to reduce connector-related failures with new installation requirements. Nearly 20 years later, little has changed: connector failures remain one of the most widespread threats to PV system safety and reliability.
“It’s absurd that one of the cheapest components in a PV system is responsible for the industry’s most notorious failures,” said David Penalva, CEO of HelioVolta. “We’re talking about a dollar’s worth of plastic and metal putting multimillion-dollar assets — and people — at risk. It’s unacceptable.”
The connector report analyzes field data, presents connector failure and remediation case studies and shares connector risk mitigation tactics for asset owners, O&M providers and EPC teams.
Key findings from HelioVolta’s field inspections include:
- 83% of projects inspected suffered from at least one connector-related issue.
- 45% of sites had major connector issues requiring urgent maintenance.
- 4.3% of projects faced critical connector failures requiring partial or total system de-energization.
- The majority of issues stemmed from preventable causes such as improper installation.
These numbers signal growing urgency for asset owners and managers, who endure increased downtime, significant maintenance costs and liability exposure when connector issues go unresolved. For example, the cost of connector failure and remediation equaled 58% of a commercial solar portfolio’s annual revenues and 19% for utility power plant.
The report also presents a clear path forward. HelioVolta outlines risk reduction strategies, such as quantifying connector-based risk for different system configurations, connector types, and installation methods during the design phase. Implementing procurement specifications to ensure cross-brand compatibility of factory-made connectors further reduces risk. Recognizing that product availability is often limited, HelioVolta delineates enhanced quality control and O&M procedures for projects with higher-risk system configurations.
HelioVolta’s report notes that preventing connector failure also requires supporting EPC and O&M field teams with better tools, training and documentation methods. Trainings must cover proper installation techniques, measuring thermal anomalies (“hot connectors”), and visual inspection guidelines. Finally, conducting third-party inspections of connectors during construction and throughout the project lifecycle helps asset owners ensure the safety of their fleet over time.
“Proper connector installation is clearly important, but assessing these components at every preventive maintenance visit is just as vital,” said Jesse Waters, CEO of Servist Energy, an O&M provider. “Since connector problems become riskier as systems operate, finding and fixing issues before disaster strikes is the best way to avoid high-cost remediation campaigns.”
The report concludes by highlighting innovations in the connector space, including the rise of crimpless connectors, efforts to standardize connector terminology led by Sandia National Laboratories and an initiative to develop a universal connector standard from National Renewable Energy Laboratory (NREL).
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