Permanent butt splicing solar panels to optimizers?

[mjbshaw]

I've got 33x 450 W solar panels and 33x Tigo TS4-A-O optimizers. Unfortunately the connectors are different brands so I can't connect the panel directly to the optimizer, and even if I could the wires are too short and need to be extended.

The normal thing to do would be to make a bunch of extension chords that convert between the connector brands. But since the Tigo optimizers are supposed to be connected to the panel first, it got me thinking: what if I treat the solar panel and optimizer as a single unit? I'll have to pre-connect them anyway when installing, and the optimizer mounts to the panel, not the rail.

And if I treat them as a single unit, what if I just make their connection to each other permanent? How bad of an idea is it to cut off the connectors on the solar panel and the optimizer (but only the connectors that go to the panel; I would leave the MC4 connectors that connect each optimizer to each other) and use a permanent butt splice (with weatherproof heat shrink, of course) + extension wire to permanently join the solar panel and optimizer together?

It would be both cheaper and, I think, safer/more reliable because connectors are more likely to fail than a permanent butt splice. I'm not sure if it might void manufacturer warranty but that seems like the only downside, perhaps? I feel crazy for even contemplating this but the more I think about it the more I kinda like the crazy idea...

 

[dopeassjackson]

I also think a MC4 connector is more likely to fail than a heat shrink solder but connector. I see lots of systems with un needed combined boxes and junction points. That's just alot of failure points to me.

 

[ghostwriter66]

I also think a MC4 connector is more likely to fail than a heat shrink solder but connector. I see lots of systems with un needed combined boxes and junction points. That's just alot of failure points to me.

Totally agree ...

 

[Mjs]

Cutting the connector off probably voids the warranty on both pieces of equipment. Granted solar panels rarely have an issue. It will also likely void the ul listing and could be a problem for the inspector if this is a permitted installation. None of which may make a difference for you, just something to be aware of.

 

[Jollysingle]

I've got 33x 450 W solar panels and 33x Tigo TS4-A-O optimizers. Unfortunately the connectors are different brands so I can't connect the panel directly to the optimizer, and even if I could the wires are too short and need to be extended.

The normal thing to do would be to make a bunch of extension chords that convert between the connector brands. But since the Tigo optimizers are supposed to be connected to the panel first, it got me thinking: what if I treat the solar panel and optimizer as a single unit? I'll have to pre-connect them anyway when installing, and the optimizer mounts to the panel, not the rail.

And if I treat them as a single unit, what if I just make their connection to each other permanent? How bad of an idea is it to cut off the connectors on the solar panel and the optimizer (but only the connectors that go to the panel; I would leave the MC4 connectors that connect each optimizer to each other) and use a permanent butt splice (with weatherproof heat shrink, of course) + extension wire to permanently join the solar panel and optimizer together?

It would be both cheaper and, I think, safer/more reliable because connectors are more likely to fail than a permanent butt splice. I'm not sure if it might void manufacturer warranty but that seems like the only downside, perhaps? I feel crazy for even contemplating this but the more I think about it the more I kinda like the crazy idea...

You can have optimizers built-in solar panels, but it will be a Chinese optimizer. Although their optimizers are matching 25 years warranty as the solar panels, but I did not find an UL Listed one.

 

[mjbshaw]

The system I’m working on is going through the city approvals process, so I need to keep product listings valid. I’m not so worried about warranty. If I can get the manufacturers to agree then I’ll consult with my electrician (who the city requires to approve any electrical work) before doing anything.

I just asked Alexus Solar (the solar panel “manufacturer”) and they said they would still honor the warranty and the UL listings should still apply. I recorded the phone call so I have proof if needed at a later date.

I’ve emailed Tigo and will share their response.

 

[TM48]

Semi permanent connections sound great.......until you want to change something.

 

[mjbshaw]

I got a call back from Tigo today and they said removing the MC4 connectors would definitely void the warranty of the optimizer. As for invalidating listings, they weren't sure.

I probably won't pursue this but it sure is tempting...