Solar Lattice

Stressor

Improper crimping

ID
stressor:improper-crimping
IRI
https://solarlattice.org/kb/stressor/improper-crimping
Status
active
Also known as
bad crimping, not-well crimped connectors

Improper crimping is a workmanship error where a connector contact is not attached properly to the cable during installation. It is one of the typical sources of connector failures, together with forcing different connector types to mate. Bad crimping is listed as one way connectors end up installed without following the manufacturer instructions, which damages DC connectors. A weak connection can lead to ground faults, arcing and fire, and quick connector defects cause a significant share of PV fires. Connector defects of this kind can cause resistance heating, open circuits and electrical risk. Connector failures are more often tied to installation issues than to aging from weather, UV and humidity. Exposure is reduced by correcting crimping and installation errors, replacing damaged connectors and checking that connector types are compatible across repaired circuits. Inverter manuals list dedicated tools for this job, such as MC4 terminal crimping pliers.

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