Although small, connectors must be able to withstand high voltages and currents as well as extreme weather conditions and temperature swings throughout the system’s entire lifetime. The foundation of a long service life lies in two key parts: the plastic housing (insulator) and the metal contact element.
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The importance of insulating material
The housing includes an insulating body with cap nut and seal. It shields the contacts and any exposed cable cores while protecting live parts from external conditions. Quality housings are tested for thermal resistance and resistance to breakage and bending, and they must do so without compromising conductivity. Fire and weather resistance are equally essential.
A shockproof earthing contact plug
The importance of contact elements
At the heart of the DC connector is the metal contact element. A spring contact that is crimped onto the connecting cables of the modules transmits the current. Its performance hinges on low electrical resistance and minimal heat generation.
A well-designed contact element maintains low contact resistance over the long term, which is key to ensuring a long service life for connectors within the module array. This stability is verified through rigorous testing.
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The importance of testing beyond norms
In addition to field testing, the original manufacturer of the MC4 connector conducts lab-based climate tests to simulate accelerated ageing. These tests go beyond standard requirements, with TÜV Rheinland certification providing independent confirmation of quality.
Small components with a big impact
In the long run, high-quality connectors deliver:
– improved plant safety
– lower risk of failure
– reduced maintenance
– consistent long-term yields
– satisfied customers
(HS/TF)
Guest author: Jurij Gerdes is Field Sales Engineer Renewable Energy at Stäubli Electrical Connectors.
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