s Challenge & Innovation|PV Label & Mounting Brackets

Challenge & Innovation

Challenges of connecting solar systems

Since 2022, as the PV industry has entered the era of 600W+, the ultra-high power and excellent efficiency of 600W+ modules have become the consensus of market application, and the current of the modules has become larger, which puts forward higher requirements for solar connectors. because the connector is an important electrical connection for the entire photovoltaic system, and a 1 MW system needs more than 4,000 pairs. It is necessary to pay attention to the real cause of the DC arc, select high-quality photovoltaic modules and connector parts, improve the construction quality of the system on-site, eliminate risks, and keep the photovoltaic system operating safely and smoothly.

DC arc is a fatal disaster for photovoltaic power plants. There are four main reasons for DC arcing: inferior connectors, low-quality components, incorrect installation operations, and material aging. One of the most common causes of DC arcing is poor contact in the connection parts and poor welding of solder joints in low-quality components. To avoid the risk of DC arcing, it is necessary to select photovoltaic modules, connectors, and cables of regular enterprises and other raw materials to avoid damage or aging of insulating materials, and professional operation; the welding of the bus strips and junction boxes of the modules must also ensure a high level. Welding quality.

The probability of DC arc generation is not intrinsically related to the current magnitude of the component. Simulation experiments show that when the positive and negative terminals of the connectors in the circuit are gradually separated, arcing will occur in both high-current circuits and low-current circuits, and there is no significant difference in arc strength. Therefore, under the same material technology and construction conditions, at a single connection point, the DC arcing probability of high-current components and low-current components is at the same level.

There are also concerns that the connector can adapt when the current increases. In this regard, the LEADER engineer said that the current-carrying capacity of the connector is generally 30-40A, and there is no pressure to cope with the increase in the power of the components. "Take the LEADER BN101A as an example, when it is matched with a 4mm² photovoltaic cable, its rated current can reach 45A, which fully meets the string current requirements and has a large margin."

LEADER has also been investing more in R&D and testing to develop safer and more efficient solar connectors, allowing our photovoltaic systems to operate more efficiently and safely.


Installers and plant operators around the world rely on Leader solar system components. Worldwide, in 2021 our products have successfully connected more than 6.8 GW PV output.
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