Types and Applications of Photovoltaic Connectors

In photovoltaic power generation systems, connectors are the connecting bridges between photovoltaic modules and key equipment such as inverters. Their quality and performance directly affect the efficiency and safety of photovoltaic systems. Photovoltaic connectors not only need to meet the transmission requirements of high voltage and high current, but also have good environmental adaptability such as waterproof and dustproof. This article will focus on several common types of photovoltaic connectors, including MC4, TYCO, Amphenol, etc., and analyze their characteristics, structures and application scenarios to help better understand and select suitable photovoltaic connectors.

1. Basic requirements for photovoltaic connectors

As a key component of the photovoltaic system, photovoltaic connectors need to have the following basic performance:

1. High voltage carrying capacity: Usually need to withstand 1000V or higher DC voltage to meet the needs of large photovoltaic systems.

2. High current carrying capacity: The current output by photovoltaic modules is large, and the connector needs to meet the current carrying capacity of 10A to 30A or even higher.

3. Waterproof and dustproof ability: Connectors are often exposed to outdoor environments, so they need to have good waterproof and dustproof performance. Usually require IP65 or higher protection level.

4. Weather resistance: Photovoltaic systems generally need to operate outdoors for more than 20 years, and the connector material should have the characteristics of UV resistance and high and low temperature resistance.

5. Low contact resistance: The connector needs to ensure stable low contact resistance to reduce energy loss and increase the efficiency of the photovoltaic system.

2. Common types of photovoltaic connectors

1. MC4 connector

MC4 connector is the most widely used connector in the photovoltaic industry. It was developed by Multi-Contact (now acquired by Stäubli). Its name MC4 stands for "Multi-Contact, 4mm". MC4 connector has the following characteristics:

- Structural features: MC4 connector adopts a single contact design, and the anode and cathode are quickly connected and disassembled through a simple snap-on structure. The interior is made of tin-plated copper material, and the shell is made of PA66 material with excellent weather resistance.

- Technical specifications: MC4 connectors generally support DC voltages of 1000V or 1500V, current capacity of about 30A, protection level of IP67, and can withstand an operating temperature range of -40℃ to +85℃.

- Safety: MC4 has a foolproof design, the anode and cathode cannot be connected incorrectly, and it has a double lock to prevent the connection from loosening. Its design complies with the relevant standards of UL and IEC and is widely used in various photovoltaic systems.

- Application occasions: Due to its excellent stability and reliability, MC4 connectors are suitable for most photovoltaic modules and are widely used in household photovoltaics, industrial and commercial photovoltaics, and large photovoltaic power stations.

2. TYCO connector

TYCO connector is another mainstream photovoltaic connector launched by TE Connectivity (formerly Tyco Electronics). Its design is similar to MC4, but there are some differences in structure and performance.

- Structural features: TYCO connector adopts waterproof O-ring design, and the contact parts are made of tin-plated copper or gold-plated copper materials, which can effectively reduce the contact resistance. The shell material is usually UV-resistant engineering plastics.

- Technical specifications: TYCO connectors usually support 1000V DC voltage, current capacity up to 25A, protection level of IP68, temperature range of -40℃ to +85℃, and have strong impact and vibration resistance.

- Safety: TYCO connectors have a lock protection function and meet TUV and UL certification standards. Its design is relatively compact, the connection reliability is high, and it is suitable for long-term outdoor use.

- Applications: TYCO connectors are widely used in Europe and Asia, and are suitable for household and small commercial photovoltaic systems. Due to its relatively low cost, it has become the choice of many small photovoltaic systems.

3. Amphenol H4 connector

Amphenol H4 connector is launched by Amphenol and is a high-performance photovoltaic connector, especially suitable for high-voltage and high-current photovoltaic systems.

- Structural features: H4 connector adopts a three-point connection design, which enhances the stability and conductivity of the contact. Its shell material has good UV resistance and anti-aging performance.

- Technical specifications: Amphenol H4 connector supports 1500V DC voltage, current capacity up to 50A, protection level is IP68, can work in an environment of -40℃ to +90℃, and has stronger weather resistance.

- Safety: The H4 connector complies with UL and TUV standards, has a foolproof design, and adopts a patented Amphenol three-point contact structure, which can effectively reduce contact resistance and ensure long-term connection stability.

- Applications: Due to its high voltage and current carrying capacity, the H4 connector is widely used in large photovoltaic power stations and photovoltaic systems with high voltage requirements.

4. Huber+Suhner RADOX connector

The RADOX connector was launched by the Swiss company Huber+Suhner and uses RADOX technical materials, which have excellent high temperature resistance and corrosion resistance.

- Structural features: The RADOX connector uses special high temperature resistant materials, the internal contacts are tinned copper, and the shell is made of highly UV-resistant RADOX material, which has excellent weather resistance.

- Technical specifications: The RADOX connector generally supports 1000V DC voltage, current capacity is about 30A, protection level reaches IP67, and temperature range is -40℃ to +120℃.

- Safety: The RADOX connector has a foolproof design, the locking mechanism ensures the stability of the connection, and has passed strict TUV and UL certification.

- Application: This connector is often used in photovoltaic systems under extreme climate conditions, especially in high temperature and high humidity areas and offshore photovoltaic applications.

5. Phoenix Contact SUNCLIX Connector

Phoenix Contact's SUNCLIX connector is a tool-free connector developed specifically for photovoltaic applications, suitable for quick installation.

- Structural features: The SUNCLIX connector uses spring crimping technology, which can be quickly connected and disassembled without the use of tools. The material is UV-resistant PA66.

- Technical specifications: The SUNCLIX connector supports 1000V DC voltage, current capacity of 25A, protection level IP68, and operating temperature range of -40℃ to +85℃.

- Application: This connector is often used in small and medium-sized photovoltaic projects. Due to its easy installation, it is particularly suitable for photovoltaic systems that need to be deployed quickly.

3. Application selection of different connectors

For different types of photovoltaic projects, you can make a reasonable choice based on the characteristics of the connector:

1. Household photovoltaic system: MC4, TYCO and SUNCLIX connectors are good choices. These connectors perform well in household photovoltaic systems and are relatively low in cost, suitable for small and medium-sized projects.

2. Commercial photovoltaic system: For small and medium-sized commercial photovoltaic systems, MC4, TYCO and Amphenol H4 connectors can meet the needs. Among them, Amphenol H4 connector is suitable for some projects with higher power due to its high current carrying capacity.

3. Large ground power station: Amphenol H4 and RADOX connectors are suitable for large photovoltaic power stations. These two connectors have higher voltage and current carrying capacity, and excellent weather resistance, suitable for long-term outdoor operation.

4. Harsh climate environment: RADOX connectors perform particularly well under extreme climate conditions. Its materials have excellent UV resistance and high temperature resistance, suitable for photovoltaic systems in high temperature, high humidity or offshore environments.

4. Summary

Photovoltaic connectors play a vital role in photovoltaic systems. Different connectors differ in structure, performance and application occasions. When selecting a photovoltaic connector, you should consider factors such as voltage, current, protection level, and environmental adaptability based on the actual needs of the project, and choose a suitable connector to ensure the efficiency and safety of the system.

Connectors such as MC4, TYCO, Amphenol H4, RADOX, and SUNCLIX show their respective advantages in different scenarios. With the rapid development of the photovoltaic industry and the complexity of photovoltaic systems, the technology of connectors will continue to innovate in the future to adapt to more diversified application needs.