Utility Scale Photovoltaic System Connector Techno-Economic Analysis

Andy Walker1, Vignesh Ramasamy1, Jal Desai1 1NREL, Golden, CO, United States /2NREL, Golden, CO, United States /3NREL, Golden, CO, United States

Connectors have traditionally been considered crucial yet somewhat overlooked elements within a PV system, playing a functional role that has been sidelined by the solar industry's emphasis on module efficiency and cost reduction in manufacturing and installation. However, faulty or deteriorated connectors significantly impact system performance, leading to power losses, heightened operational and maintenance demands, and potentially catastrophic failures, including fire hazards. Furthermore, degraded or failed connectors raise concerns about increased insurance premiums, higher levelized cost-of-energy (LCOE), and reduced confidence in the reliability of solar power generation. This work describes an integrated technical and economic analysis to quantify the impact of connector failure on PV lifecycle economic metrics, including energy yield, O&M expenses and LCOE. This work includes the modeling of O&M expenses and energy production losses related to degraded and failed connectors based on operating temperature and the impact of connector degradation and failure on a plant’s LCOE. This data matters because DC power losses lower the amount of kWh (energy yield) that could otherwise be converted to PV project revenues, and replacement of failed connectors impacts project O&M expenses. The results of this analysis provide insights into the value of quality connectors, proper installation methods, and/or more rigorous testing standards for connector product qualification.