SOLARLOK Connectivity Systems for PV Installers Building a greener tomorrow TE Connectivity is committed to bringing the promise of renewable energy to the world. The SOLARLOK product offering provides a simple and reliable interconnection of solar systems. TE has worked with leaders in the solar industry to lower costs, increase reliability, and devise new and innovative ways to create and apply solar products. Early involvement pays off in competition advantage With approximately 7,000 engineers and 11 global design centers, In short, we can help you achieve a sustainable competitive plus manufacturing facilities in approximately 25 countries, we put advantage. Whether it’s showing you the best existing products, a premium on innovation when it comes to helping companies solve offering a value added solution or designing a new product, tough design problems. Talking to us early on in your design cycle our commitment to advanced engineering and world-class will give you the full benefit of our expertise. manufacturing delivers innovation that can advance any solar project. Our Electronic Components segment is a world leader We can help you: in passive electronic components, including connectors and interconnect systems, relays, switches, circuit protection devices, Shorten the design cycle touchscreens, sensors, and wire and cable. TE’s ability to serve Reduce costs your present and future requirements is realized through the Increase reliability synergies of a strong R&D program and our expertise in materials Design for manufacturability science, product design and process engineering, all supported by our network of 5000-plus knowledgeable, sales representatives and customer service personnel. TE Global Design Centers 1 : Harrisburg, PA : USA 2 : Greensboro/Winston-Salem, NC : USA 3 : Menlo Park, CA : USA Solar Manufacturing Facilities 4 : Wilsonville, OR : USA 5 : Eatontown, NJ : USA A : Trutnov, Czech Republic 6 : Kawasaki, Japan B : Greensboro, NC : USA 7 : Bensheim, Germany C : Empalme, Mexico 8 : Shanghai, China D : Hermosilla, Mexico 9 : Kessel-Lo, Belgium E : DongGuann, China 10 : s’Hertogenbosch, Netherlands F : Shanghai, China 11 : Kyungsan, Korea G : QingDao, China SOLARLOK Connectivity Systems for PV Installers Mechanical, Environmental and Electrical Testing Capabilities Force-deflection curves are generated to verify that spring contact properties meet design criteria. Contact resistance and temperature rise are measured and recorded automatically. These parameters help to establish/verify current carrying capacity, and de-rating curves. Test samples are isolated to minimize the influence of external variables such as air movement. Components/assemblies are exposed to cold, heat, moisture, and temperature change. Thermal shock is accomplished with the 2-chamber method. Environmental chambers operate from -70°C to +180°C enabling simulation of real-world conditions. Slow-motion bending and vibration testing simulates line movements in the wire, stressing the crimped termination. Industrial atmospheres are generated with a gas mixture of SO2, H2S, NO2 and Cl2. 3D X-ray computer tomography provides high resolution three-dimensional non-destructive analysis capability. Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 2 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Manufacturing Capabilities The Trutnov, Czech Republic facility offers a repeatable manufacturing process which TE manufactures the produces a 100% automatically inspected and electrically tested junction box. For quality SOLARLOK product control purposes, each junction jox is “laser etched” with a unique serial number. line on state of the art manufacturing Our electrical test equipment has four independent heads to automatically test each connection rail and diode in the popular four rail junction box. Assembly equipment equipment. automatically verifies the production of the cable assemblies and attachment to the junction box. The true position of the contact in the mating coupler housing and proper torque of the screw nut are some of the critical process checks made to each unit. A vision system is incorporated into the junction box assembly equipment. Polarization and molded features are inspected by the same vision system to contribute to the production of a quality product and a repeatable manufacturing process. The SOLARLOK product is currently manufactured in Europe, Asia and the USA. TE Manufacturing Facility in Trutnov, Czech Republic Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 3 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers The SOLARLOK Product Concept System Features Junction Box • Variable wiring options • Simple, fast and cost-effective assembly • Flat, low profile design • High current carrying capacity • Good thermal balance • Connectorized or direct wire configurations • Up to four outputs possible • Up to six internal rails • Customer-specific solutions • TÜV and UL approved Cable Couplers • Simple on-site processing • Mating safety provided by keyed housings • Semi-automatic assembly capability possible • Multiple plugging and unplugging cycles • Accomodates solar cable with different insula tion diameters • High current carrying capacity Market expansion of the formerly regulated The junction box concept is based on a flexible, • Wide temperature operating range energy supply sector, increased global open system structure, which allows serial as well environmental awareness and governments as parallel interconnection via direct wire connect • TÜV and UL approved committing themselves to more stringent or separable connectors. Within the junc tion box, environmental targets have opened up new up to six termination places rails are available for Solar Cable opportunities for the photovoltaic industry. photovoltaic foil connection. If required by the • Dual wall insulation customer, the junction box can be delivered Having served a niche market in the past, the • Electron beam cross-linked pre-configured with diodes, jumpers, plug photovoltaics industry now has the opportunity • Excellent resistance to U.V., water, connectors, and solar cable pigtails. to move into mass production, realizing ozone, fluids, salt, general weathering economies of scale and gaining a greater The male and female cable couplers were • Excellent resistance to abrasion market share of the world’s energy mix. designed for high voltage and high current- • Halogen free, flame retardant, low toxicity carrying capa city in addition to the well- TE has contributed to the establishment of this • Very low smoke emissions established IP 67 sealing requirement in the environmentally-friendly tech nology with the • Excellent flexibility and stripping performance photovoltaic industry. Mating safety is provided introduction of its SOLARLOK connector system. • Temperature Rating : –40°C up to +125°C by polarity keyed housings, fully shrouded contacts, reliable high cycle life, and a squeeze • Nominal Voltage : Vo/V 1800/3000 VAC, The SOLARLOK connector system delivers a to release connection system. In addition, a wide 2600 VDC flexible system solution for easy and reliable temperature range and fulfill ment of worldwide interconnections from photovoltaic modules to • Test Voltage : 6KV, 50Hz, 5min standards for photovoltaic connection systems the DC/AC converter. The entire system concept ≥ • Bending Radius : 5 x outer diameter complement the robust product specification. is based on cost-effective and reliable pr ocessing • TÜV and UL approved of individual interconnection system components. This significantly reduces installation costs of the solar energy system. Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 4 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Table of Contents Combiner Box Combiner Box ........................................................................................................................page : 8 Transition Box ...................................................................................................................... page : 9 Connectors Cable Coupler : Standard Line ......................................................................................page : 10 Cable Coupler : Slim Line ................................................................................................. page : 11 Contacts ................................................................................................................................ page : 12 T-Branch Connector .......................................................................................................... page : 13 AC Inverter Connector .....................................................................................................page : 14 Labels Labels ..................................................................................................................................... page : 15 Solar Cables Solar Cables ....................................................................................................................page : 16-17 Wiring Example with Extension Cables ....................................................................page : 18 Grounding System Grounding System : Grounding Bolt ...........................................................................page : 19 Grounding System : Grounding Clip ..........................................................................page : 20 Connectors Interconnection Examples .......................................................................................page : 22-23 Tooling Application Tooling ................................................................................................... page : 24-25 Guidelines Assembly and Installation Guidelines ................................................................ page : 26-29 Numerical Index ...........................................................................................................page : 30-31 Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 5 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 Junction Box Female Cable Coupler Male Cable Coupler Grounding Connector Combiner Box Caution Solar Circuit Label DC Disconnect Label Solar Disconnect Label Solar Wire SOLARLOK Connectivity Systems for PV Installers 5-String Combiner Box Technical Data Output Wire : Cu ONLY, 90°C, 14-4 AWG Maximum Voltage : 600 V Maximum Output Current : 75 A Maximum Continuous Current : 60 A Maximum Current Per String : 15 A Maximum Fuse Rating : 15 A Maximum Module Isc Per String : 9.6 A Enclosure Type : NEMA 3 Ambient Temperature : -35°C to 50°C [-31°C to 122°F] Negative Output Terminal Torque : 4 Nm [35 in-lbs] Positive Output Terminal Torque : 14-10 AWG = 4 Nm [35 in-lbs] : 8 AWG = 4.5 Nm [40 in-lbs] : 6.4 AWG = 5.1 Nm [45 in-lbs] Ground Terminal Block Torque : 4Nm [35 in-lbs] Features & Benefits • Combines up to 5 PV strings The SOLARLOK combiner box assembly is used to combine up to five strings in a • Converts to standard wires preterminated connectorized weather-resistant enclosure to meet National Electric Code • Completely pre-assembled (NEC) requirements for series fusing of photovoltaic (PV) modules (solar panels). • Plug & play design provides labor savings and minimizes installer The combiner box assembly consists of a box, cover (with hinges), transparent dead front error during installation lid (under the cover), and 10 pre-terminated SOLARLOK connectors each with a removable • Uses existing products currently dust cover. The box features 4 knockouts (for output wiring), lock tab, mounting slots and produced by Tyco Electronics pre-wired grounding bolt. • UL 1741 listed The interior of the box holds 5 holder fuse blocks pre-wired to the positive SOLARLOK connectors, 5 terminal blocks pre-wired to the negative SOLARLOK connectors, and an equipment terminal block used to ground the equipment. Fuses are not included. Part Number : 1954283-1 Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 8 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Transition Box Technical Data Output Wire : Cu ONLY, 90°C, 14-4 AWG Maximum Voltage : 600 V Maximum Current Per String : 20 A Maximum Module Isc Per String : 12.8 A Enclosure Type : NEMA 3 Ambient Temperature : -35°C to 70°C [-31°C to 122°F] Output Terminal Torque : 4 Nm [35 in-lbs] Features & Benefits • Converts to standard wires The SOLARLOK transition box is used to convert outdoor wire to more cost effective • Completely pre-assembled building wire for use in protective conduit. The transition box assembly consists of a • Plug & play design provides labor pre-terminated connectorized weather-resistant enclosure to meet National Electric Code savings and minimizes installer (NEC) requirements, a cover (with hinges), a transparent dead front lid (under the cover), error during installation and 10 pre-terminated SOLARLOK connectors, 5 pre-wired to the negative terminal • Uses existing products currently block and 5 pre-wired to the positive terminal block, each with a removable dust cover. produced by TE The box features 4 knockouts (for output wiring), a lock tab, mounting slots and a • UL 1741 listed pre-wired SOLARLOK grounding bolt. Part Number : 2106916-1 Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 9 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Cable Coupler : Standard Line Female Cable Coupler (kit with screw-machined contact) Gen 3 Seal Part Number Gen 2 Seal Part Number Cable Outer Diameter Cable Outer Diameter Wire Size 2 5.5 mm to 8.0 mm 4.5 mm to 6.0 mm mm AWG Keying Package Quantity 1394462-1 4-1394462-6 2.5 14 Plus 100 1394462-3 4-1394462-8 4.0 12 Plus 100 5-1394462-5 6-1394462-3 6.0 10 Plus 100 1394462-2 4-1394462-7 2.5 14 Minus 100 1394462-4 4-1394462-9 4.0 12 Minus 100 Technical Data 5-1394462-6 6-1394462-4 6.0 10 Minus 100 Electrical Features Current Rating : Up to 25 A Withstanding Voltage : 1000 V DC Contact Resistance : 1 mΩ typical Mechanical Features Dimensions : Diameter 18 mm (.71 inch) Protection Degree : IP 67, mated Contact Finish : Silver plated Standards UL approved TÜV approved Male Cable Coupler (kit with screw-machined contact) Gen 3 Seal Part Number Gen 2 Seal Part Number Cable Outer Diameter Cable Outer Diameter Wire Size 2 5.5 mm to 8.0 mm 4.5 mm to 6.0 mm Keying Package Quantity mm AWG 1394461-1 1394461-7 2.5 14 Plus 100 1394461-3 7-1394461-0 4.0 12 Plus 100 6-1394461-5 7-1394461-3 6.0 10 Plus 100 1394461-2 1394461-8 2.5 14 Minus 100 1394461-4 7-1394461-1 4.0 12 Minus 100 Technical Data 6-1394461-6 7-1394461-4 6.0 10 Minus 100 Electrical Features 6-1394461-1 6-1394461-3 2.5 14 Neutral 100 Current Rating : Up to 25 A Withstanding Voltage : 1000 V DC 6-1394461-2 7-1394461-2 4.0 12 Neutral 100 Contact Resistance : 1 mΩ typical 6-1394461-4 7-1394461-5 6.0 10 Neutral 100 Mechanical Features Dimensions : Diameter 18 mm (.71 inch) Protection Degree : IP 67, mated Contact Finish : Silver plated Standards UL approved TÜV approved Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 10 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Cable Coupler : Slim Line Female Cable Coupler (kit with screw-machined contact) Wire Size 2 Part Number Keying Package Quantity mm AWG 1987559-1 2.5 14 Plus 100 1-1987559-1 4.0 12 Plus 100 1987559-2 2.5 14 Minus 100 1-1987559-2 4.0 12 Minus 100 Female Cable Coupler (without contact : only housing and sealing) Technical Data Wire Size 2 Electrical Features Part Number mm AWG Keying Package Quantity Current Rating 1987287-1 -- -- Plus 2,500 : Up to 25 A Withstanding Voltage : 1000 V DC 1987287-2 -- -- Minus 2,500 Contact Resistance : 1 mΩ typical Mechanical Features Dimensions : Diameter 18 mm (.71 inch) Protection Degree : IP 67, mated Contact Finish : Silver plated Standards UL pending TÜV approved Male Cable Coupler (kit with screw-machined contact) Wire Size 2 Part Number Keying Package Quantity mm AWG 1987558-1 2.5 14 Plus 100 1-1987558-1 4.0 12 Plus 100 1987558-2 2.5 14 Minus 100 1-1987558-2 4.0 12 Minus 100 1987558-3 2.5 14 Neutral 100 1-1987558-3 4.0 12 Neutral 100 Technical Data Electrical Features Male Cable Coupler (without contact : only housing and sealing) Current Rating : Up to 25 A Withstanding Voltage : 1000 V DC Wire Size 2 Contact Resistance : 1 mΩ typical Part Number mm AWG Keying Package Quantity 1987286-4 -- -- Plus 2,500 Mechanical Features Dimensions : Diameter 18 mm (.71 inch) 1987286-5 -- -- Minus 2,500 Protection Degree : IP 67, mated 1987286-6 -- -- Neutral 2,500 Contact Finish : Silver plated Standards UL pending TÜV approved Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 11 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Replacement Contacts Female Contacts (Screw-Machined) Technical Data Material : Copper alloy, silver plated Materials 2 Part Number Wire Size (mm ) Wire Size (AWG) Package Quantity Contact : Silver plated, copper alloy 1987281-1 2.5 AWG 14 100 1987281-2 4.0 AWG 12 100 Electrical Features 1987281-3 6.0 AWG 10 100 Current Rating : Up to 25 A 24.5 4.1 Male Contacts (Screw-Machined) Material : Copper alloy, silver plated 2 Part Number Wire Size (mm ) Wire Size (AWG) Package Quantity 1987280-1 2.5 AWG 14 100 1987280-2 4.0 AWG 12 100 1987280-4 6.0 AWG 10 100 26.75 4.1 Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 12 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers T-Branch Connector Parallel Interconnection using T-Branch Connector (Male-to-Male) Part Number Keying Package Quantity 1534611-1 Plus 20 1534611-2 Minus 20 * TÜV and UL approved Parallel Interconnection using T-Branch Connector (Female-to-Male) Part Number Keying Package Quantity 1740277-1 Plus 20 1740277-2 Minus 20 * TÜV and UL approved Safety Clips (Optional) Part Number Description Package Quantity 1534226-1 Pivoted 100 NEC 2008/USA UTE C15-712/ 2106207-1* 100 France *Instruction Sheet : 408-10296 Female Housing : with strap Female Housing : no strap Connector Dust Covers Part Number Description Package Quantity 1987423-1 Female housing cover with strap 100 1394739-1 Male housing cover with strap 100 1987424-1 Female housing no strap 100 1987419-1 Male housing no strap 100 Note : Dust cap are reusable Male Housing : with strap Male Housing : no strap Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 13 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers AC Inverter Connector Technical Data Electrical Features Current Rating : 25 A per Pole Voltage Rating : 400 V Mechanical Features Protection Degree : IP67 (mated) No. of Positions : 5 Poles Temperature Range : -40°C up to +50°C 2 2 - 6.0 mm Wire Size Range : 2.5 mm Standards Approvals VDE Certified Panel Mount Plug Cable Length 2 Part Number Nut (5 x 4.0 mm ) Package Quantity 1740483-1 Metal 200 mm 24 1740483-2 Plastic 200 mm 24 Free Hanging Receptacle Cable Length 2 Part Number Nut (5 x 4.0 mm ) Package Quantity 1740479-1 - - 24 Complete Sets Cable Length 2 Part Number Nut (5 x 4.0 mm ) Package Quantity 1740493-1 Metal 200 mm 24 1740493-2 Plastic 200 mm 24 Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 14 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Labels Solar Identification Labels Quantity/Roll TE Ordering Description SAP Part Number Label Description SOL-SD-104076-4-0.1 CN4616-000 Solar Disconnect SOL-DCD-104100-4-0.1 CN4619-000 DC Disconnect 5 rolls of 100 SOL-DPS-104019-4-0.1 CN4618-000 Warning - Dual Power Sources SOL-ESH-104019-4-0.1 CN4617-000 Warning - Electric Shock Hazard SOL-SD-104076-4-0.5 CL3803-000 Solar Disconnect SOL-DCD-104100-4-0. 5 CL3806-000 DC Disconnect 500 SOL-DPS-104019-4-0. 5 CL3804-000 Warning - Dual Power Sources SOL-ESH-104019-4-0. 5 CL3805-000 Warning - Electric Shock Hazard Solar Rating Labels Quantity/Roll TE Ordering Description SAP Part Number Label Description SOL-SRS-127508N-.1-4 CR0780-000 System Inverter Rating SOL-CP-127508N-.1-X CR0781-000 Laminate for above label SOL-SRS-127698N-.1-4 CR0782-000 System Charge Controller rating 5 rolls of 100 SOL-CP-127698N-.1-X CR0783-000 Laminate for above label SOL-SRS-812120N-.1-4 CR0784-000 Generic System Rating SOL-CP-812120N-.1-X CR0785-000 Laminate for above label SOL-SRS-127508N-.5-4 CR0786-000 System Inverter Rating SOL-CP-127508N-.5-X CR0787-000 Laminate for above label SOL-SRS-127698N-.5-4 CR0788-000 System Charge Controller Rating 500 SOL-CP-127698N-.5-X CR0789-000 Laminate for above label SOL-SRS-812120N-.5-4 CR0791-000 Generic System Rating SOL-CP-812120N-.5-X CR0792-000 Laminate for above label Solar Reflective Labels Quantity/Roll TE Ordering Description SAP Part Number Label Description SOL-SEC-305254-4-0.1 CN6557-000 CAUTION : SOLAR ELECTRICAL SYSTEM 500 SOL-CSC-159254-4-0.1 CN4615-000 CAUTION : SOLAR CIRCUIT Note : Solar Label Print Kits : 300 dpi Pre-print services are also available SOL-PRINT-300 : PN 2-1878569-8 for “peel and stick” application with Kit Contents Description Part Number all pertinent electrical information. 300 dpi thermal transfer printer E23401-000 T212M-PRINTER Inquire with TE for further information 1330-0607-T200 Black resin thermal transfer ribbon E45478-000 regarding this service. Label printing software CC8954-000 PEP-5-PRO-DGLUSB (For Americas only) SOL-PRINT-310 : PN 2-1878569-9 Kit Contents Description Part Number T3112-PRINTER 300 dpi thermal transfer printer CR2120-000 1330-0607-10 Black resin thermal transfer ribbon 742412-000 Label printing software CC8954-000 PEP-5-PRO-DGLUSB Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 15 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Solar Cable : Global TÜV and UL 4703 Technical Data Material Conductor : Stranded tin plated copper Insulation : Electron beam cross-linked polyolefin Sheath : Electron beam cross-linked halogen free polyolefin Color : Black, Blue, Red Electrical Features Voltage Rating (as per TÜV requirement 600/1000 VAC, 1800 V DC) As part of expanding the SOLARLOK product line, TE produces wire that is designed to meet : 1800/3000 VAC the harsh environmental conditions typical of photovoltaic installations. The flexible, dual wall, : 2600 VDC halogen free and cross linked solar wire offers long term stability with TÜV UL approval. Wire Size Range Its outstanding features include: high resistance against environmental conditions such as 2 : 2.5 mm (AWG 14) humidity, UV-radiation and ozone. In addition, it has excellent resistance to abrasion and 2 : 4.0 mm (AWG 12) temperature extremes. The wire has a high dielectric withstanding voltage and due to its 2 : 6.0 mm (AWG 10) fine-stranded, tin plated copper conductor, it is easy to handle, bend, route, and to strip. Standards TÜV certified according to 2PfG Global TÜV and UL 4703 1169/08.2007 (PV1-F) : RG0021060 Cross Section Conductor Reel UL certified according to UL Outline 4703 Diameter Weight Max Color Part Number Package Construction 2 (mm) (kg/km) mm AWG Diameter (PV wire, type ZKLA) : E317230 (m) no. x mm (mm) Fire Performance : IEC 60332-1-2, UL 1581 2.5 14 50 x 0,26 1.95 6,65 +0,15/-0,1 62.5 500 956297-4 1080/VW1, EN 50267-2-1/2, EN 50305 4.0 12 56 x 0,31 2.50 6,90 +/-0,10 75.8 500 956298-4 Conductor : IEC 60228 class 5 (stranded 956299-4 6.0 10 84 x 0,31 3.05 7,35 +0,3/-0,25 95.5 500 and flexible tin plated copper wire) Black 1-956297-4 2.5 14 50 x 0,26 1.95 6,65 +0,15/-0,1 62.5 100 1-956298-4 4.0 12 56 x 0,31 2.50 6,90 +/-0,10 75.8 100 1-956299-4 6.0 10 84 x 0,31 3.05 7,35 +0,3/-0,25 95.5 100 Features & Benefits 956297-5 2.5 14 50 x 0,26 1.95 6,65 +0,15/-0,1 62.5 500 • TÜV and UL approved 956298-5 4.0 12 56 x 0,31 2.50 6,90 +/-0,10 75.8 500 • Dual wall insulation 956299-5 6.0 10 84 x 0,31 3.05 7,35 +0,3/-0,25 95.5 500 • Electron beam cross-linked Red 2.5 14 50 x 0,26 1.95 6,65 +0,15/-0,1 62.5 100 1-956297-5 • Excellent resistance to abrasion 1-956298-5 4.0 12 56 x 0,31 2.50 6,90 +/-0,10 75.8 100 • Halogen free, flame retardant, 1-956299-5 6.0 10 84 x 0,31 3.05 7,35 +0,3/-0,25 95.5 100 low toxicity 956297-6 2.5 14 50 x 0,26 1.95 6,65 +0,15/-0,1 62.5 500 • Excellent flexibility and stripping 4.0 12 56 x 0,31 2.50 6,90 +/-0,10 75.8 500 956298-6 performance 956299-6 6.0 10 84 x 0,31 3.05 7,35 +0,3/-0,25 95.5 500 2 2 • Wire size from 2.5 mm up to 6.0 mm Blue 1-956297-6 2.5 14 50 x 0,26 1.95 6,65 +0,15/-0,1 62.5 100 1-956298-6 4.0 12 56 x 0,31 2.50 6,90 +/-0,10 75.8 100 1-956299-6 6.0 10 84 x 0,31 3.05 7,35 +0,3/-0,25 95.5 100 Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 16 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Solar Cable : Type USE-2 Technical Data Electrical Features Voltage Rating : 600 V DC Mechanical Features Operating Temperature : up to +90°C Standards UL certified to 854 (USE-2) : 10-14 AWG UL File E314122 and E314123 USE-2 approved solar cable – for the North American market UL approved cable is offered Features & Benefits in 10 through 14 AWG. This cable is approved for USE-2, XHHW-2, RHW-2, or RHH. Sunlight, • Insulation provides resistance gasoline, and petroleum resistance make this an ideal cable for any solar installation in to U.V., water, ozone, fluids, salt, North America. A high strand count increases the flexibility and tinned copper wire strands gasoline, and petroleum general ease the use of this cable. weathering • High strand count conductor Type USE-2 (For US Installation), UL Approved Cable provides flexibility and Cross Section Diameter Reel Package Color Part Number stripping performance AWG (inch) (ft) • Multiple cable diameters available 1986166-1 14 0.17 7,500 1986166-2 14 0.17 500 1986166-3 14 0.17 2,500 12 0.19 7,500 1986165-1 1986165-2 12 0.19 500 Black 1986165-3 12 0.19 2,500 1986164-1 10 0.21 7,500 1986164-2 10 0.21 500 1986164-3 10 0.21 2,500 Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 17 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Wiring Example with Extension Cables Male Cable Coupler (+) Female Cable Coupler (+) 1394461-3 1394462-3 Male Cable Coupler (-) Female Cable Coupler (-) 1394461-4 1394462-4 Female Cable Coupler (+) Female Cable Coupler (+) 1394462-3 1394462-3 Inverter Female Cable Coupler (-) Female Cable Coupler (-) 1394462-4 1394462-4 Female Cable Coupler (-) Female Cable Coupler (+) 1394462-4 1394462-3 2 Configuration Example at 4.0 mm Cable Assembly Cable Assembly Version Part Numbers for Cable Length 1 m 3 m 5 m 10 m 20 m 1987376-1 1987376-2 1987376-3 1987376-4 1987376-5 1-1987376-1 1-1987376-2 1-1987376-3 1-1987376-4 1-1987376-5 2-1987376-1 2-1987376-2 2-1987376-3 2-1987376-4 2-1987376-5 3-1987376-1 3-1987376-2 3-1987376-3 3-1987376-4 3-1987376-5 4-1987376-1 4-1987376-2 4-1987376-3 4-1987376-4 4-1987376-5 More variants (cable length, wire diameter, color) upon request. Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 18 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Grounding System : Grounding Bolt Technical Data Materials Connector & Hardware : Stainless Steel (Passivated) Electrical Features Short Term Current Test (UL 467) : 6 AWG = 1530A (6 seconds) : 8 AWG = 1180A (4 seconds) : 10 AWG = 750A (4 seconds) : 12 AWG = 470A (4 seconds) Mechanical Features Securness Test (ul 486A-B) : 6 AWG = 18lbs (30 minutes) Product Offering : 8 AWG = 8lbs (30 minutes) Part Number Description Thread Dim “A” Package Quantity : 10 AWG = 5lbs (30 minutes) 2058729-1 6-12 AWG #8-32 UNC .380 100 : 12 AWG = 5lbs (30 minutes) 2106831-1 Long Shank 6-12 AWG #10-32 UNF .700 100 Pull out Test (ul 486A-B) *Instruction Sheet : 408-10262 : 6 AWG = 100lbs (1 minute) : 8 AWG = 90lbs (1 minute) : 10 AWG = 80lbs (1 minute) Dimensions : 12 AWG = 70lbs (1 minute) Application Tooling Top View Side View Bottom View Flex socket wrench or wrenches A Standards UL 467 listed UL File #E69905 A requirement for UL 1703 solar panel listing CSA C22.2 No. 41-07 Edge Features Features & Benefits • Rugged and compact hex bolt design made from stainless steel. • Quick and easy mounting procedures. • Bottom edge feature cuts through the annodized aluminum surface when securing the hex bolt to the module frame. • Standard tooling can be used with the hex nuts. Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 19 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Grounding System : Grounding Clip Technical Data Materials Housing : Durable PBT 30% glass filled polyester. Material is outdoor & UV rated Contact : High conductivity, copper Electrical Features Meets the tough requirements of photovoltaic grounding applications and the 2008 National Electrical Code. Mechanical Features Meets the tough requirements for grounding applications for solid Product Offering copper wire. 12 AWG applications will withstand Part Number Screw Nut Package Quantity Wire Size 70lbs pull while the 10 AWG 1954381-1 #10-32 Thread Cutting None 100 10-12 AWG applications will withstand 80lbs pull 1954381-2 #8-32 Pan Head #8-32 100 10-12 AWG 1954381-3 #8-32 Pan Head #8-32 Star Washer Nut 100 10-12 AWG Application Tooling 1954381-4 #8-32 Long Shark none 100 10-12 AWG No special tooling is required -- only 2 1954381-5 #10-32 Thread Cutting none 100 6 mm flathead screwdrivers and channel *Instruction Sheet : 408-10160 lock pliers (optional) 3 Easy Steps to Ground Your PV System Standards Ul 467 listed Insert... ... Push... ... Ready UL File #E69905 A requirement for UL 1703 solar panel listing CSA C22.2 No. 41-07 Dimensions Features & Benefits • Product comes as an assembled kit that includes an attachment screw #8-32 Pan • Contact design provides 4 points of Head Screw contact to the ground wire for high reliability 32.5 • Product is easy to install with simple tools that are readily available 16.8 • Removal of the installed ground wire 24.5 requires a screwdriver, this meeting the #10-32 Thread tooled extration requirements Cutting Screw • RoHS compliant 94.5 Closed Position 10.0 Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 20 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Engineering Notes Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 21 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Interconnection Examples Serial Interconnection for Junction Boxes with Cable Glands 2 (4.0 mm / 12 AWG Wiring) 1394462-4 6-1394461-2 1394461-4 1394462-3 1394462-4 1394462-3 1394738-4 1394738-3 DC/AC Converter Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 22 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Interconnection Examples (continued) Serial Interconnection for Junction Boxes with Plug Connectors 2 (4.0 mm / 12 AWG Wiring) 1394462-4 1394462-3 1394462-3 1394462-4 1394462-4 1394462-3 1394738-4 1394738-3 DC/AC Converter Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 23 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Application Tooling Cable Assembly Tooling Specs Hand Crimp Tool for Screw Machine Contacts Includes Crimp Head & Locator 2 2 PN : 1-1579004-1 (1.5 mm & 2.5 mm ) 2 2 : 1-1579004-2 (4.0 mm & 6.0 mm ) Extraction Tool (suitable for all wire sizes) PN : 1102855-3 Insulator Stripper Includes length stop for all wire size (Suitable for our Solar Cable) 2 2 PN : 4-1579002-2 (1.5 mm , 2.5 mm , 2 2 4.0 mm and 6.0 mm ) SOLARLOK Electric Terminator CS 200 Base Machine : PN : 539630-1 Electrical Terminator CS 200 for Screw Machine Contacts Adaptor for Crimp Head PN : 1579000-4 Crimp Head 2 2 (1.5 mm and 2.5 mm ) PN : 7-1579001-8 Crimp Head 2 2 (4.0 mm and 6.0 mm ) PN : 7-1579001-9 Crimp Head (AWG 10) PN : 8-1579001-2 Crimp Head (AWG 12) PN : 5-1579001-5 Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 24 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Application Tooling (continued) Junction Box Assembly Tooling Wire Spring Clamp Tool PN : 1579007-2 Dioden/Jumper Spring Clamp Tool PN : 1579007-5 Foil Spring Clamp Tools 6 Rail Large Box (Shown) PN : 1579007-3 5 Rail (Not Shown) PN : 1740969-3 4 Rail Medium Box (Not Shown) PN : 1740969-1 3 Rail Small Box (Not Shown) PN : 1740969-2 Connector Assembly Tooling Hexagon Spanner Head for torque Wrench PN : 523229-1 Torque Wrench, PN : 2161345-1 Field Service Kit SOLARLOK INSTALLER STARTER KIT Part Number : 1534858-1 (Metric Wire) Part Number : 5-1579010-4 Included in Kit: Included in Kit: Hand Crimp Tool Hand Crimp Tool PN : 1-1579004-2 PN : 1-1579004-2 Extraction Tool Extraction Tool PN : 1102855-3 PN : 1102855-3 Insulation Stripper • 20 Cable Coupler PN : 4-1579002-2 (Housings, Plus and Minus coded) *Cable outer diameter 5.5 mm to 8.0 mm • 100 Cable Coupler (Housings, Plus and Minus coded) • Crimp Contacts 2 *Cable outer diameter 5.5 mm to 8.0 mm (6.0 mm ) • Crimp Contacts • SOLARLOK Field Manual 2 2 (4.0 mm and 6.0 mm ) • Instruction Sheets • Pinch ring • Seals Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 25 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Assembly and Installation Guidelines SOLARLOK plug connectors ATTENTION : This connector is to be used only to interconnect firmly fixed cables DO NOT DISCONNECT UNDER LOAD : Current path should only be disconnected using approved disconnect devices. SOLARLOK component cable can be labeled with label PN : 1718077-1. (DO NOT DISCONNECT UNDER LOAD) PROTECT AGAINST SHOCK : Ensure that conductors and their associated connectors are separated from opposite polarity components. Mounting and installation must be done by qualified and trained staff considering IMPORTANT NOTE all applying safety regulations. Failure to follow all instructions in Application Specification 114-18488 (available at www.tycoelectronics.com/documents), including using only approved TE tooling (if applicable), can result in improper installation and/or crimping which is dangerous and may cause or contribute to electrical fires. Should be used only by individuals with proper training and experience. General Comments Any kind of pollution (dust, oil, humidity, etc.) during the assembly process or to the unmated connector can degrade contact and connector performance. This applies in particular to the seals and the crimping of the contacts. A clean assembly environment is essential. Termination of the Cable • SOLARLOK connectors use different crimp contacts for various wire gauges. 2 2 2 Wires and Crimping of • Possible wire gauges are 2.5 mm , 4.0 mm , and 6.0 mm , AWG 14, AWG 12 and AWG 10. the Contacts • The tools to be used are selected based upon the wire gauge. • For the application specification, please refer to specification #114-18488. 3.1 Handling When assembling the connectors, the following sequence must be followed: of the Connectors 1 : Stripping the wire to 9 +/- 1mm without damaging the strands (please refer to application specification #114-74013) Fig.1 Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 26 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Assembly and Installation Guidelines (continued) 3.1 Handling of the 2 : Insert the stripped wire into the wire crimp barrel until it stops. Connectors (continued) 3 : While holding the wire in place, squeeze tool handles together until ratchet releases. Fig. 2 4 : Push contact with cable into the connector housing (include seal/pinch ring combination and backshell) until you hear the contact is locked into position. To verify contact engagement, give a gentle pull back on the cable to be sure the contact is locked. “CLICK” Fig. 3 5 : Tighten backshell nut to 1.3 +0.2 Nm. (For tooling, please refer to page 25, item 4) Fig. 4 Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 27 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Assembly and Installation Guidelines (continued) 3.2 Connector Latching When mating the SOLARLOK connectors, ensure the following: 1 : Connectors labeled with a plus or minus are keyed and can only be mated to similarly marked and keyed connectors. CAUTION : THE “NEUTRAL” DESIGNATED PIN CONNECTORS INCORPORATE NO KEYING FEATURES AND MUST ONLY BE USED FOR SERIAL INTERCONNECTION OF PHOTOVOLTAIC MODULES. THE NEUTRAL PRODUCT SHOULD NOT BE USED WHERE MAINTAINING POLARITY IS CRITICAL. 2 : The polarity of the “neutral” connector should be labeled with part number : 1394725-1 or 1394725-2. 3 : The connector system is fully latched only when the latches are flush with the mating connectors. After the connector is fully latched, the optional latch locking clip may be snapped, with a click, into place. Fig. 5 (female connector) 3.3 Disconnecting CAUTION : DO NOT DISCONNECTED UNDER LOAD. Disconnect circuit load before unplugging connectors by using approved devices (DC main switch, inverter connector and other devices). Cable assemblies should be labeled with part number : 1394470-1. Fig. 6 1 : The locking mechanism is opened by depressing the latches. 2 : Pull out the connectors. While depressing the latches, disconnect the connector by pulling the connector halves apart. Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 28 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Assembly and Installation Guidelines (continued) Application Examples Fig. 7 : Serial (Wire Diagram) Fig. 8 : Parallel (Wire Diagram) Storage See product specification 108-18701 Tooling Find available tools for the contact crimping on page 24 (please specify the required wire gauge). An extraction tool (part number 1102855-3) is needed to disassemble the connector components. The tool is used to unlock the contact retention features, after which the contact can be removed and re-used one time if necessary. Technical Description Fig. 9 Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 29 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers PV Installers Numerical Index Part Number Page Part Number Page Part Number Page CN4615-000 15 956298-6 16 4-1394462-7 10 CN6557-000 15 1-956298-4 16 4-1394462-8 10 CN4616-000 15 1-956298-5 16 4-1394462-9 10 CN4619-000 15 1-956298-6 16 5-1394462-6 10 CN4618-000 15 956299-4 16 5-1394462-5 10 CN4617-000 15 956299-5 16 6-1394462-3 10 CN3803-000 15 956299-6 16 6-1394462-4 10 CN3806-000 15 1-956299-4 16 1394739-1 13 CN3804-000 15 1-956299-5 16 1534226-1 13 CN3805-000 15 1-956299-6 16 1534611-1 13 CR0780-000 15 1394461-4 10 1534611-2 13 CR0781-000 15 1394461-7 10 1740277-1 13 CR0782-000 15 1394461-8 10 1740277-2 13 CR0783-000 15 6-1394461-1 10 1740479-1 14 CR0784-000 15 6-1394461-2 10 1740483-1 14 CR0785-000 15 6-1394461-3 10 1740483-2 14 CR0786-000 15 6-1394461-4 10 1740493-1 14 CR0787-000 15 6-1394461-5 10 1740493-2 14 CR0788-000 15 6-1394461-6 10 1-1740939-2 10 CR0789-000 15 7-1394461-0 10 1-1740940-3 10 CR0791-000 15 7-1394461-1 10 1-1740940-4 10 CR0792-000 15 7-1394461-2 10 2-1878569-8 14 956297-4 16 7-1394461-3 10 2-1878569-9 14 956297-5 16 7-1394461-4 10 1954283-1 8 956297-6 16 7-1394461-5 10 1954381-1 20 1-956297-4 16 4-1394462-6 10 1954381-2 20 1-956297-5 16 1394462-1 10 1954381-3 20 1-956297-6 16 1394462-2 10 1954381-4 20 956298-4 16 1394462-3 10 1954381-5 20 956298-5 16 1394462-4 10 1986164-1 17 Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 30 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers PV Installers Numerical Index (Continued) Tooling Part Number Page Part Number Page Part Number Page 1986164-2 17 1-1987376-3 18 2058729-1 19 1986164-3 17 1-1987376-4 18 2106207-1 13 1986165-1 17 1-1987376-5 18 2106916-1 9 1986165-2 17 2-1987376-1 18 2106831-1 19 1986165-3 17 2-1987376-2 18 1740969-1 25 1986166-1 17 2-1987376-3 18 523229-1 25 1986166-2 17 2-1987376-4 18 539630-1 24 1986166-3 17 2-1987376-5 18 1102855-3 24,25 1987280-1 12 3-1987376-1 18 1-1579004-1 24 1987280-2 12 3-1987376-2 18 1-1579004-2 24,25 1987280-3 12 3-1987376-3 18 1534858-1 25 1987280-4 12 3-1987376-4 18 1579000-4 24 1987280-5 12 3-1987376-5 18 8-1579001-2 24 1987281-1 12 4-1987376-1 18 5-1579001-5 24 1987281-2 12 4-1987376-2 18 7-1579001-8 24 1987281-3 12 4-1987376-3 18 7-1579001-9 24 1987281-4 12 4-1987376-4 18 4-1579002-2 24,25 1987281-5 12 4-1987376-5 18 1579007-2 25 1987286-4 11 1987419-1 13 1579007-3 25 1987286-5 11 1987423-1 13 1579007-5 25 1987286-6 11 1987558-1 11 5-1579010-4 25 1987287-1 11 1987558-2 11 1740969-2 25 1987287-2 11 1987558-3 11 1740969-3 25 1987376-1 18 1-1987558-1 11 2161345-1 25 1987376-2 18 1-1987558-2 11 1987376-3 18 1-1987558-3 11 1987376-4 18 1987559-1 11 1987376-5 18 1987559-2 11 1-1987376-1 18 1-1987559-1 11 1-1987376-2 18 1-1987559-2 11 Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 31 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 SOLARLOK Connectivity Systems for PV Installers Engineering Notes Dimensions are in inches and millimeters unless otherwise specified. USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686 te.com/solar 32 Values in brackets are standard equivalents. Dimensions are shown Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999 Catalog 3-1773458-6 | Issue Date 04/2011 for reference purposes only. Specifications subject to change. Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015 We are a leading manufacturer of electronic components and solutions for solar energy. Our growing presence in the photovoltaic and solar thermal industry is backed by our innovative, extensive and high quality products to meet your individual needs. FOR MORE INFORMATION TE Technical Support Center Internet: te.com/help USA: +1 (800) 522-6752 Canada: +1 (905) 475-6222 Mexico +52 (0) 55-1106-0800 Latin/S. America: +54 (0) 11-4733-2200 Germany: +49 (0) 6251-133-1999 UK: +44 (0) 800-267666 France: +33 (0) 1-3420-8686 Netherlands: +31 (0) 73-6246-999 China: +86 (0) 400-820-6015 Part numbers in this brochure are RoHS Compliant*, unless marked otherwise. *as defined www.te.com/leadfree te.com © 2011 Tyco Electronics Corporation, a TE Connectivity Ltd. company. All Rights Reserved. 3-1773458-6 CIS FP 3M 04/2011 SOLARLOK, TE Connectivity, TE connectivity (logo) and TE (logo) are trademarks. Other logos, product and/or company names might be trademarks of their respective owners. While TE has made every reasonable effort to ensure the accuracy of the information in this brochure, TE does not guarantee that it is error-free, nor does TE make any other representation, warranty or guarantee that the information is accurate, correct, reliable or current. TE reserves the right to make any adjustments to the information contained herein at any time without notice. TE expressly disclaims all implied warranties regarding the information contained herein, including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose. The dimensions in this catalog are for reference purposes only and are subject to change without notice. Specifications are subject to change without notice. Consult TE for the latest dimensions and design specifications.