Stäubli has released the guidelines on DC connectors in single-axis tracker applications to prevent premature failures
The continuous movement of trackers introduces cyclic mechanical stress on DC wiring and connectors, which can cause failures if not properly managed
Stäubli addressed this issue through extensive laboratory testing and field inspections of tracker-based PV systems to understand how cyclic mechanical loads affect DC connectors
Trackers are designed to increase solar energy capture by orienting PV modules toward the sun throughout the day. Single-axis and dual-axis trackers are the 2 main types of trackers used to boost energy yield by following the path of the sun, with the former type now a standard feature of large-scale PV plants. However, unlike fixed-tilt systems, their continuous rotation introduces additional stress on DC connections.
Stäubli, a PV connector technology provider headquartered in Switzerland, has released a study that underlines best practices for safe and reliable DC connections in single-axis tracker installations.
As is common knowledge in the PV industry, single-axis trackers are gaining increased deployment due to high energy yield and compatibility with bifacial modules. Given their continuous rotation, single-axis trackers introduce cyclic mechanical stress to the DC wiring and connectors. If not properly managed, this dynamic loading can cause premature connector failures, elevated contact resistance, and potential safety risks.
In this study, Stäubli specifically examined the impact of cyclic mechanical loads on DC connectors under varying installation conditions. These assessments showed that improper wiring practices, such as insufficient strain relief or incorrect connector integration, can significantly amplify the negative effects of tracker movement. Failures were not limited to one brand but occurred across different connector types when subjected to poor installation.
The findings show that reliable performance is determined not only by the quality of the components but also by how they are installed. Installers need to follow the manufacturer’s assembly instructions carefully and use certified crimping and assembly tools. In addition, connectors must be kept mechanically isolated from the forces generated by tracker movement.
Stäubli also provides practical services to support installation quality, including training, first-row installation guidance, DC health checks, and root-cause failure analysis. As Grayson Maurer, Head of Renewable Energy Services at Stäubli North America, explains: “Ensuring the mechanical isolation of connectors is not just about static force protection but equally about safeguarding against dynamic forces inherently present in tracker-based installations.”
By combining connector technology with proper application practices, the company aims to reduce long-term risks for asset owners and ensure that the higher yields promised by single-axis trackers are matched by reliable electrical performance.
TaiyangNews has been following the development of trackers through dedicated market surveys and virtual conferences on the subject. For more details about tracker technologies and market leaders, see our free report Solar Trackers Market Survey 2024 here.