Industry Safety Alert: Overlooked AC Connections Are Becoming a System Risk

Recently, according to reports from major financial media, a fire incident occurred in an energy storage system in the Australian market.
The investigation indicated that the incident was not caused by batteries or core inverter components, but by abnormal overheating at the AC connection interface.
Fortunately, no injuries were reported.

This incident once again highlights a critical safety issue for the solar and energy storage industry.

Small Components, Big Risks

In PV and energy storage systems, connectors, terminals, and plugs are often treated as standard or secondary components.
However, under long-term high-load operation, poor contact, improper crimping, or insufficient material performance can lead to localized temperature rise and, over time, develop into serious system-level safety risks.

As PV plants and energy storage projects continue to expand globally, basic connection components are increasingly becoming the most overlooked — yet most critical — weak point in system safety.

Our Approach to AC Connection Reliability

As a one-stop provider of PV and energy storage accessories, NewSun PV considers connection safety a starting point of system design, not an afterthought.

Our AC connector solutions are built on the following principles:

• Compliance with IEC, CE, and TÜV international standards

• Ultra-low contact resistance (below 0.25 mΩ) to minimize heat generation

• Stable and reliable crimping and locking structures

• Consistent control of materials, manufacturing, and quality

• Designed for long-term operation under high-load conditions

We believe that true system safety comes from every connection point being properly engineered and strictly controlled.

Recommendations for the Industry

• Include AC connection points in critical inspection routines

• Conduct regular thermal imaging inspections

• Prioritize certified, traceable, and quality-controlled connection components

• Strengthen systematic risk management for “small components”

Safety should not focus only on major equipment.
Connection reliability defines the long-term value of the system.

NSPV has been dedicated to one-stop PV accessory solutions for over 16 years.