Roofs of Hazard: PV connector risks continue to plague solar portfolios according to HelioVolta findings

Who is ready for some more bad news this week? Field inspection and analytics firm HelioVolta reports the solar industry is still struggling to address the big – costly! – risks associated with PV connectors in the field.

Despite years of attention, PV connectors remain one of the most common sources of system failure across commercial and utility-scale solar. In its new report, PV Connectors: The State of the Field, HelioVolta shares insights from independent inspections at hundreds of projects totaling more than 5 GW of capacity.

Among the findings:

  • 83% of projects inspected had at least one connector-related issue
  • 45% of sites had major connector problems that required urgent maintenance
  • 4.3% of systems faced critical connector failures that required partial or full shutdown
  • Most of these issues stem from improper installation

“It’s absurd that one of the cheapest components in a PV system is responsible for the industry’s most notorious failures,” said David Penalva, CEO of HelioVolta. “We’re talking about a dollar’s worth of plastic and metal putting multimillion-dollar assets—and people—at risk. It’s unacceptable.”

HelioVolta’s white paper presents anonymized case studies of connector-related failures and outlines risk mitigation strategies for asset owners, EPCs, and O&M providers. It also includes financial modeling that shows just how expensive these failures can be.

Want one example? Connectors cause 58% loss of annual revenues

  • Project: 1 MW Retail Rooftop Project
  • Problem: A fire caused by an overheated arcing connector severely damaged PV system equipment and the roof of a retail store.
  • Cause: The root cause was systemic bad crimps during installation on all homeruns
  • Impact: Store closes for one day. System de-energized for inspection and remediation. And another 1-month PORTFIO-WIDE de-energization to complete inspections and rework of that EPC’s nine other sites (a 100 MW portfolio).
  • Total cost: $558,450, which equates to 58% of annual revenues lost. You should download the report to see the full cost breakdown.

“Proper connector installation is clearly important, but assessing these components at every preventive maintenance visit is just as vital,” commented Jesse Waters, CEO of Servist Energy, an O&M provider. “Since connector problems become riskier as systems operate, finding and fixing issues before disaster strikes is the best way to avoid high-cost remediation campaigns.”

Quantifying PV connector risks in design

The HelioVolta report does a good job of outlining 15 potential system configurations, and quantifying the connector-based risk for those configurations, connector types, and installation methods during the design phase.

“The number and type of connectors in a PV system can increase the risk of safety events by nearly 20x,” the authors note.

The path to the least risky starting score? A UL 3741 compliant system with no MLPE and factory machine-made module connectors. Anything field-made is going to “jumper” up the score, if you will.

MLPE will inherently increase the risks by having more points of connection – a fact we’ve been pointing out for a decade now. Plus, a 1:1 MLPE to module ratio often requires jumpers to prevent cross-mating.

But HelioVolta also highlights the compounding impact of supply issues. It’s not uncommon for MLPE and solar modules, both with factory-made connectors, to arrive on site with connectors that are not compatible. As HelioVolta notes, this leaves two choices that add significantly more risk based on their findings in the field:

  • Cut off and replace the factory-made connectors with matching field-made connectors, potentially voiding the PV module and/or MLPE warranty.
  • Use jumpers, which are cables with connectors at both ends, to bridge incompatible connectors and avoid inter-mating.

HelioVolta suggests implementing procurement specifications to ensure cross-brand compatibility. Recognizing that product availability is often limited, HelioVolta delineates enhanced quality control and O&M procedures for projects with higher-risk system configurations.

Intermating PV connectors is not code compliant per NEC 2023

Merely following NEC 2023 can solve some of this. HelioVolta finds 40% of all major and critical issues observed relate to intermating PV connectors. Intermated PV connectors are not compliant with NEC 2023. Per Penalva:

“Intermated connectors are not compliant unless their positive and negative parts have been tested together and UL certified for intermateability. Typically, brands only do this testing and UL certification with their own models; for example, MC4 and MC4 Evo2 connectors from Staubli were tested and UL certified together, and they are approved to intermate — it’s two parts from different models, but they still have the same manufacturer.”

So, just meeting NEC 2023 with a UL certified 6703 connector would reduce the risks noted in this report by 40%? Penalva confirms: “We are confident that 40% of the issues reported could be avoided by complying with NEC 2023”

Any good PV connector news?

My two cents per Watt? Codes and standards really need to step up and address this — and help might be on the way. The HelioVolta report concludes by highlighting innovations in the connector space, including the rise of crimpless connectors, efforts to standardize connector terminology led by Sandia National Laboratories, and an initiative to develop a universal connector standard from National Renewable Energy Laboratory (NREL).

Final word: Preventable.

The standout line in the report: “Most connector issues were readily avoidable: inter-mating (i.e., crossmating, mismatch), exposure to the elements, and under or over-torquing make up over 60% of all connector issues.”

HelioVolta’s report notes that preventing connector failure also requires supporting EPC and O&M field teams with better tools, training, and documentation methods. Trainings must cover proper installation techniques, measuring thermal anomalies (“hot connectors”), and visual inspection guidelines.

Finally, conducting third-party inspections of connectors during construction and throughout the project lifecycle helps asset owners ensure the safety of their fleet over time.

To download the white paper, visit www.heliovolta.com/connector-white-paper.

Tags:

See Discussion, Leave A Comment

  • -8
  • Nancee Angelo
    June 23, 2025 23:21:35

    This is an open job position to be a website chat assistant. We currently have lots of different businesses hiring for these positions in all countries right now. Website chat assistants are the people who answer the customer’s live chat support or sales questions on a business’s website. The work is done online, normally from home. Read the full details here to complete your application if you are interested.

    —–> https://bit.ly/3GI4OZ0

    Reply
  • Ellis Hmelnitsky
    June 24, 2025 09:37:42

    Access ChatGPT, Claude, Gemini Pro , Kling AI, LLaMA, Mistral, DALL.E, LLaMa & more—all from a single dashboard.

    No subscriptions or no monthly fees—pay once and enjoy lifetime access.

    Automatically switch between AI models based on task requirements.

    And much more … http://www.novaai.expert/AI-IntelliKit

    Reply
  • Merri Palumbo
    June 24, 2025 10:00:44

    Hello

    Claim Your $447K AI-Powered Business Today

    Access a fully built, AI-powered business valued at $447K—designed to generate up to $417.95 per sale. No tech skills or hard work required.

    Interested in unlocking this done-for-you income stream?

    Want in => https://rb.gy/mv6qbh

    Best regards
    Merri

    If you wish to unsubscribe, please reply to this email.

    Reply
  • great points altogether, you simply won a logo new reader.
    What might you recommend in regards to your put up that
    you simply made some days ago? Any certain?

    Here is my webpage – Nostalgia DJ Mix

    Reply
  • June 25, 2025 18:54:39

    É perfeito momento para fazer alguns planos para o futuro e é hora de ser feliz.

    Eu li este post e se eu pudesse eu quero sugerir a você algumas coisas interessantes ou
    sugestões. Talvez você pudesse escrever os próximos artigos referindo-se
    a este artigo. Eu quero ler ainda mais coisas sobre isso!

    Reply
  • Madge Leeper
    June 26, 2025 03:38:35

    Stop hopping between AI tools — we’ve unified them.

    Get lifetime access to ChatGPT, Claude, Gemini Pro, DALL·E, Mistral, LLaMA, Kling AI and more — from a single, unified dashboard.

    [✓ | » | ➤] No subscriptions, no monthly fees — pay once, use forever

    [✓ | » | ➤] Auto-switch between models — let the system choose the best AI for each task

    [✓ | » | ➤] Built for creators, pros, and AI power users

    *[! | ] Limited lifetime access — only available for the first 250 users

    >> Click here to unlock it now → http://www.novaai.expert/AI-IntelliKit

    Reply
  • Dominga Iverson
    June 26, 2025 11:31:10

    Hello

    Claim Your $447K AI-Powered Business Today

    Access a fully built, AI-powered business valued at $447K—designed to generate up to $417.95 per sale. No tech skills or hard work required.

    Interested in unlocking this done-for-you income stream?

    Want in => https://rb.gy/mv6qbh

    Best regards
    Dominga

    If you wish to unsubscribe, please reply to this email.

    Reply
  • Alfonso Neustadt
    June 27, 2025 07:21:55

    The World’s simplest income generation website is ready to deposit commissions in your account daily.

    Zero experience required – 100% Done-For-You set up

    Takes 15 minutes to set up & can generate income 24/7/365

    Perfect solution for any age, ability or background

    3 Simple & Free steps to get your new website working for you

    More Info —-> https://bit.ly/4lfYOFK

    Reply
  • Marquita Johnson
    June 27, 2025 17:07:15

    Hello

    Claim Your $447K AI-Powered Business Today

    Access a fully built, AI-powered business valued at $447K—designed to generate up to $417.95 per sale. No tech skills or hard work required.

    Interested in unlocking this done-for-you income stream?

    Want in => https://rb.gy/mv6qbh

    Best regards
    Marquita

    If you wish to unsubscribe, please reply to this email.

    Reply
  • Arlie Alcock
    June 28, 2025 00:29:03

    LAUNCH YOUR OWN AMAZON PUBLISHING EMPIRE IN 60 SECONDS!

    World’s First Amazon Publishing AI Assistant

    Instantly Research Profitable Keywords, Create & Publish

    To 310 Million Amazon Users Without Writing A Single Word

    No Writing. No Tech Skills. No Experience Needed!

    more https://www.novaai.expert/KindleMint

    Reply
  • Misty Fulkerson
    June 28, 2025 03:26:30

    Hello

    Claim Your $447K AI-Powered Business Today

    Access a fully built, AI-powered business valued at $447K—designed to generate up to $417.95 per sale. No tech skills or hard work required.

    Interested in unlocking this done-for-you income stream?

    Want in => https://rb.gy/mv6qbh

    Best regards
    Misty

    If you wish to unsubscribe, please reply to this email.

    Reply
  • Matthias Drakeford
    June 28, 2025 05:51:08

    The Futuristic All-In-One AI Voice Platform Clones Any Voice, Translates It Into 20+ Global Languages, & Creates Human-Like Voices In 60 Seconds Flat – With Real Emotions, Voice Modulations, Global Accents & Multilingual Fluency.

    Powered By Revolutionary Vocal DNA Technology, That Turns Any Text, Audio, & Video Into A Human-Like Voice – That Sounds So REAL, As If A Human Is Talking…

    And much more … https://www.novaai.expert/ToneCraftAI

    Reply
  • Thaddeus Lininger
    June 28, 2025 12:31:58

    Hello

    Boost Sales Fast with Rapid Traffic Flow

    Want more traffic and real buyers? Rapid Traffic Flow sends high-converting traffic straight to your site-fast, easy, and hands-free.
    Perfect for boosting product visibility and increasing sales without extra effort.

    Start getting real results now: https://rb.gy/bx4rvz

    Best regards
    Thaddeus

    If you wish to unsubscribe, please reply to this email.

    Reply
  • Jeanna Remer
    June 29, 2025 18:37:42

    Hello

    Claim Your $447K AI-Powered Business Today

    Access a fully built, AI-powered business valued at $447K—designed to generate up to $417.95 per sale. No tech skills or hard work required.

    Interested in unlocking this done-for-you income stream?

    Want in => https://rb.gy/mv6qbh

    Best regards
    Jeanna

    If you wish to unsubscribe, please reply to this email.

    Reply
  • Tiffany Inouye
    June 30, 2025 03:45:47

    Hello

    Boost Sales Fast with Rapid Traffic Flow

    Want more traffic and real buyers? Rapid Traffic Flow sends high-converting traffic straight to your site-fast, easy, and hands-free.
    Perfect for boosting product visibility and increasing sales without extra effort.

    Start getting real results now: https://rb.gy/bx4rvz

    Best regards
    Tiffany

    If you wish to unsubscribe, please reply to this email.

    Reply
  • Melvina Lemieux
    June 30, 2025 19:56:57

    30-Second Trick Turns My Phone Into a $500/Day Cash Machine”
    Just Tap The “Secret Button” To Cash In From This $385 Billion WiFi Profit Loophole!

    And much more … https://www.novaai.expert/PassiveIncome

    Reply
  • Curtis Faircloth
    July 1, 2025 12:05:56

    Hello

    Boost Sales Fast with Rapid Traffic Flow

    Want more traffic and real buyers? Rapid Traffic Flow sends high-converting traffic straight to your site-fast, easy, and hands-free.
    Perfect for boosting product visibility and increasing sales without extra effort.

    Start getting real results now: https://rb.gy/bx4rvz

    Best regards
    Curtis

    If you wish to unsubscribe, please reply to this email.

    Reply
  • Jonelle Rickel
    July 2, 2025 11:37:25

    Hello

    Boost Sales Fast with Rapid Traffic Flow

    Want more traffic and real buyers? Rapid Traffic Flow sends high-converting traffic straight to your site-fast, easy, and hands-free.
    Perfect for boosting product visibility and increasing sales without extra effort.

    Start getting real results now: https://rb.gy/bx4rvz

    Best regards
    Jonelle

    If you wish to unsubscribe, please reply to this email.

    Reply
  • Tanja Wardill
    July 3, 2025 21:55:37

    Still subscribing to five different AI platforms?

    It ends here.

    Introducing a disruptive AI hub that gives you 1-click entry to over 350+ top-tier tools — with no API fees, no monthly charges, no hidden costs.

    Use Synthesia from a single portal.
    No dev skills. No setup. No waiting.

    Automate workflows with ease.
    Everything you need. Nothing you don’t.

    Why pay when you can unlock it now for zero recurring fees?

    Don’t get locked out https://fixnova.site/5356681

    Reply
  • Elane Probst
    July 5, 2025 11:16:39

    You Don’t Need Tech Skills To Succeed. Just a Funnel That Handles the Heavy Lifting For You Ready to Go in Minutes From Now
    Launch Your Own Funnel Featuring Share-Worthy AI Tools Built to Spark Engagement
    Built-In Tools Help You Get Traffic + Preloaded Emails Feature Your Affiliate Links
    No Ads. No Writing. No Tech Skills Needed – Just Follow a Few Simple Steps
    EMAILS, GIVEAWAYS & BUILT-IN TRAFFIC TOOLS

    more … https://www.novaai.expert/WarriorFunnels

    Reply
  • Pearlene Plate
    July 5, 2025 22:58:19

    Hello

    Boost Sales Fast with Rapid Traffic Flow

    Want more traffic and real buyers? Rapid Traffic Flow sends high-converting traffic straight to your site-fast, easy, and hands-free.
    Perfect for boosting product visibility and increasing sales without extra effort.

    Start getting real results now: https://rb.gy/bx4rvz

    Best regards
    Pearlene

    If you wish to unsubscribe, please reply to this email.

    Reply
  • Shad Brisbane
    July 6, 2025 12:28:24

    Hello

    Boost Sales Fast with Rapid Traffic Flow

    Want more traffic and real buyers? Rapid Traffic Flow sends high-converting traffic straight to your site-fast, easy, and hands-free.
    Perfect for boosting product visibility and increasing sales without extra effort.

    Start getting real results now: https://rb.gy/bx4rvz

    Best regards
    Shad

    If you wish to unsubscribe, please reply to this email.

    Reply
  • Zac Goff
    July 6, 2025 14:55:11

    The Futuristic All-In-One AI Voice Platform Clones Any Voice, Translates It Into 20+ Global Languages, & Creates Human-Like Voices In 60 Seconds Flat – With Real Emotions, Voice Modulations, Global Accents & Multilingual Fluency.

    Powered By Revolutionary Vocal DNA Technology, That Turns Any Text, Audio, & Video Into A Human-Like Voice – That Sounds So REAL, As If A Human Is Talking…

    And much more … http://www.novaai.expert/ToneCraftAI

    Reply
  • Modesto Marks
    July 7, 2025 23:24:48

    Hello

    Boost Sales Fast with Rapid Traffic Flow

    Want more traffic and real buyers? Rapid Traffic Flow sends high-converting traffic straight to your site-fast, easy, and hands-free.
    Perfect for boosting product visibility and increasing sales without extra effort.

    Start getting real results now: https://rb.gy/bx4rvz

    Best regards
    Modesto

    If you wish to unsubscribe, please reply to this email.

    Reply