Photovoltaic connector behaviour under accelerated fretting testing regimes

Photovoltaic modules have no moving parts and last upwards of 25 years with no maintenance aside from occasional cleaning. The installation of modules in building facades and other structures has necessitated the use of push fit connectors to enable quick and easy inter-module DC electrical connection. New applications for photovoltaics such as roof shingles (tiles) place further performance demands on connectors. The day-night variation in temperature within a PV roof for example, creates component expansion. This paper details the behaviour of a tin plated copper photovoltaic connector under small amplitude fretting tests (10-100 ?m) using a specially developed accelerated lifetime test rig. The mated connector creates a high force, multiple point contact between the male and female components by the use of a prestressed spring collar. The study shows that a transition amplitude exists (~13 ?m) above which gross slip at the connector interface appears to occur. This causes a gradual linear increase in contact resistance, followed by a sudden change to rapid wearing of the tin plating on both the connector surfaces and spring collar, leading to connector failure. Below the transition amplitude, partial slip at the connector interface is observed which creates a stable, low contact resistance. The paper highlights the need to maintain a partial slip/stick condition within a PV connector for long term contact resistance stability. The implication of this requirement for photovoltaic connector design and application is discussed, considering the benefits of flexible connector housings and lubricants in particular.

10 to 100 micron, 13 micron, 25 y, pv connector, pv roof, sn-cu, accelerated fretting testing regimes, accelerated lifetime test rig building facades, cleaning, component expansion, connector failure connector interface, connector surfaces, connectors, contact resistance, day-night temperature variation, flexible connector housings, gross slip, inter-module dcelectrical connection, long term contact resistance stability, lubricants, maintenance, mated connector, module installation, multiple point contact, partial slip, partial slip/stick condition, photovoltaic applications, photovoltaic connector, photovoltaic connector design, photovoltaic modules prestressed spring collar, push fit connectors, rapid wear, roof shingles, roof tiles, small amplitude fretting tests, spring collar, stable low contact resistance, tin plated copper photovoltaic connector, tin plating wear, transition amplitude

0780366670

10.1109/HOLM.2001.953212

203-208

IEEE

Bahaj, A.B.

a64074cc-2b6e-43df-adac-a8437e7f1b37

James, P.

da0be14a-aa63-46a7-8646-a37f9a02a71b

McBride, J.

d9429c29-9361-4747-9ba3-376297cb8770

7 August 2002

Bahaj, A.B.

a64074cc-2b6e-43df-adac-a8437e7f1b37

James, P.

da0be14a-aa63-46a7-8646-a37f9a02a71b

McBride, J.

d9429c29-9361-4747-9ba3-376297cb8770

Bahaj, A.B., James, P. and McBride, J. (2002) Photovoltaic connector behaviour under accelerated fretting testing regimes. In Proceedings of the Forty-Seventh IEEE Holm Conference on Electrical Contacts, 2001. IEEE. pp. 203-208 . (doi:10.1109/HOLM.2001.953212).

Record type: Conference or Workshop Item (Paper)

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More information

Published date: 7 August 2002

Venue - Dates: Forty-Seventh IEEE Holm Conference on Electrical Contacts, Montreal, Canada, 2001-09-10 - 2001-09-12

Keywords: 10 to 100 micron, 13 micron, 25 y, pv connector, pv roof, sn-cu, accelerated fretting testing regimes, accelerated lifetime test rig building facades, cleaning, component expansion, connector failure connector interface, connector surfaces, connectors, contact resistance, day-night temperature variation, flexible connector housings, gross slip, inter-module dcelectrical connection, long term contact resistance stability, lubricants, maintenance, mated connector, module installation, multiple point contact, partial slip, partial slip/stick condition, photovoltaic applications, photovoltaic connector, photovoltaic connector design, photovoltaic modules prestressed spring collar, push fit connectors, rapid wear, roof shingles, roof tiles, small amplitude fretting tests, spring collar, stable low contact resistance, tin plated copper photovoltaic connector, tin plating wear, transition amplitude

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