Solar Lattice

Mitigation

Connector replacement

ID
mit:connector-replacement
IRI
https://solarlattice.org/kb/mit/connector-replacement
Status
active

Connector replacement is a corrective action for a connector defect: damaged or mismatched DC connectors are swapped out for sound ones. It matters because faulty connectors can cause resistance heating, open circuits, ground faults, arcing and fire hazards. Faulty connectors are found mainly by visual inspection, with infrared thermography as a supporting check. Tactile inspection with the circuit safely isolated, string current comparison and insulation-resistance testing can also help. Replace any connector that poses a direct safety risk. Keep checking the ones you leave in place with regular inspections. During the repair, also fix crimping and installation errors, and confirm that the connector types are compatible across the repaired circuit. Use proper crimping tools, have trained staff do the work, and keep connectors and cables away from humidity during installation. When fitting a connector, crimp the contact with a suitable tool, push it in until it clicks into place, and tighten the swivel nut to the manufacturer's torque. If the installer substitutes connectors, sign a contract so the warranty stays valid. Some makers void the warranty if you cut a power optimizer's connectors.

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