A Y-Sol(R) Photovoltaic Cable Assemblies Connectors and Junction Boxes 2010 Hermetic Sealed - One Step Process Why Hermetic Sealed? One Step Process What is the meaning of Hermetic Sealed? Hermetic Sealed is a one step overmolding process. In a one step process the connector is molded into its final shape and makes a solid connection with the cable. No screws or extra parts are needed. The overmolding forms a permanent hermetic sealing around the cable and contact (fig 1). Yamaichi has developed this technology for the connectors Y-Sol3, Y-Sol3 T-Junction, Y-Sol4 and for the Thin Film Junction Box. These products come ready-to-plug to the customer. 100% tested for easy and safe assembly. For worldwide usage, the products are tested and certified by TUV and UL. fig 1. shows a 3D Hermetic Sealed Y-Sol3 T-Junction Customer advantages with our cable assemblies The Hermetic Sealed technology combines the advantages of cost and quality - Less installation time requiredbecause of overmolded cable assemblies which are pre-assembled and ready-to-plug". - Permanent and safe operation of the PV plant. Y-Sol connectors fulfil the IP68 protection class. The overmolding process protects the inner parts and contacts. - Safe power transmission of up to 30A. - Standard products are available as well as customised solutions. - Long life time of the complete assembly even under harsh environmental conditions. - Cross linked cables are used as standard. Customer advantages with our Thin Film Junction Box The TF J-Box from Yamaichi is delivered with cables and overmolded connectors. In addition to the advantages of our cable assemblies, the Hermetic Sealed TF J-Box has the following features: - Delivered as a pre-assembled Hermetic Sealed system, complete with cables and connectors. - Configuration according to customer requirements. - Fully overmolded integrated bypass diode. This guarantees safe operation under different lighting conditions or shadowing. - The Hermetic Sealed diode is homogenously surrounded by plastic material. Heat generated by the diode is absorbed. This means reduced stress on the diode and longer life time (fig 2). Diode fully overmolded fig 2. The bypass diode is overmolded by plastic material. During shadowing the diode will heat up.This heat is absorbed and eliminated. The plastic material has a 30 times higher heat conductivity than air. Y-Sol3 Cable Assemblies Y-Sol3 connector is a ready-made solar cable assembly, "ready-to-plug" in your PV installation. 100% controlled quality by Yamaichi. Ready-to-Plug Y-Sol3 O 3mm contacts without locking Part Number (example) and various combinations Y-SOL3AOV - F1 - 4U - 1000 - GM* Series No. for Overmolded (Hermetic Sealed) M1 = F1 = M2 = F2 = Male (with Partial Strip off) Female (with Partial Strip off) Male (with Blank Cut) Female (with Blank Cut) Cable Cross Section 2T = 2.5mm, with TUV 4U = 4.0mm, with TUV and UL 4T = 4.0mm, with TUV 6T = 6.0mm, with TUV Overall Length in mm (e.g. 1000 = 1 meter) Certified: acc. to EN50521 (TUV) acc. to UL 1703 Specifications GM* = Internal Style No. (determined by Yamaichi) For final part numbers please contact Yamaichi before odering Description Y-SOL3 Diameter 13.5mm Degree of protection IP68 (plugged) and IP20 (unplugged) Protection class II Cable cross section 2.5mm, 4.0mm and 6.0mm Ambient temperature -40C to +85C Contact resistance < 5m (typ. value 1m up to 3m) Voltage rating 1,000 V DC acc. to TUV EN50521 Current rating 30A (based on 4mm cross section) Extraction force > 89 Newton Cable pull-out force > 350 Newton 600 V DC acc. to UL 1703 Y-Sol3 T-Junction Assemblies Y-Sol3 T-Junction is a ready-made solar cable assembly, "ready-to-plug" in your PV installation. It is made according to customer requirements. The number of T-Junctions and adapter cables can be freely specified. 100% controlled quality by Yamaichi. Y-Sol3 T-Junction O 3mm overmolded cable harness for connection of PV panels in parallel configuration. Part Number (example) and various combinations Y-SOL3T - F 4 3 - 6T - 3200 - GM* Series No. for Overmolded (Hermetic Sealed) M = Male F = Female Number of T-Junctions (e.g. 4) Number of Adapter Cables (e.g. 3) Cable Cross Section 6T = 6.0mm, with TUV 6U = 6.0mm, with TUV and UL Overall Length in mm (e.g. 3200 = 3.2 meter) GM* = Internal Style No. (determined by Yamaichi) For final part numbers please contact Yamaichi before odering Certified: acc. to EN50521 (TUV) acc. to UL 1703 Specifications Description Y-SOL3 T-Junction Diameter 17mm Degree of protection IP68 (plugged) and IP20 (unplugged) Protection class II Cable cross section 6.0mm Ambient temperature -40C to +85C Contact resistance < 5m (typ. value 1m up to 3m) Voltage rating 1,000 V DC acc. to TUV EN50521 Current rating 30A (based on 6mm) Extraction force > 89 Newton Cable pull-out force > 350 Newton 600 V DC acc. to UL 1703 Y-Sol4 Cable Assemblies Y-Sol4 is a ready-made solar cable assembly, "ready-to-plug" in your PV installation. The Y-Sol4 connector has a security locking function. Once closed a release tool is necesary to re-open the connection. 100% controlled quality by Yamaichi. Ready-to-Plug Y-Sol4 Part Number (example) and various combinations O 4mm contacts with locking Y-SOL4AOV - M1 - 4T - 1000 - GM* Series No. for Overmolded (Hermetic Sealed) Y-SOL4 release tool Part Number Y-SOL4-RELEASE-TOOL-SR M1 = Male (with Partial Strip off) F1 = Female (with Partial Strip off) M2 = Male (with Blank Cut) F2 = Female (with Blank Cut) Cable Cross Section 1U = 1.5mm, with TUV and UL 2U = 2.5mm, with TUV and UL 4T = 4.0mm, with TUV Overall Length in mm (e.g. 1000 = 1 meter) GM* = Internal Style No. (determined by Yamaichi) Certified: acc. to EN50521 (TUV) acc. to UL 1703 For final part numbers please contact Yamaichi before odering Specifications Description Y-SOL4 Height 12mm Degree of protection IP68 (plugged) and IP20 (unplugged) Protection class II Cable cross section 1.5mm, 2.5mm and 4.0mm Ambient temperature -40C to +85C Contact resistance < 5m (typ. value 1m up to 3m) Voltage rating 1,000 V DC acc. to TUV EN50521 Current rating 30A (based on 4mm cross section) Extraction force > 89 Newton Cable pull-out force > 350 Newton 600 V DC acc. to UL 1703 Y-Sol4 Crimp Assembly Connector (C.A.T.) The Y-Sol4 C.A.T. (Crimp Assembly Type) is a connector for field installation by crimp connection. The connector comes in male and female types and has only two parts to connect with the cable. The cable is assembled by using a standard crimp tool. This crimping can be done manually or automatically. Crimp Type Y-Sol4 C.A.T. Part Number (example) and various combinations O 4mm contacts - crimp type assembly PVP0402 - 102 - 02 02 - 00* Series No. for Crimp Assembly Type PVP0402 = Plug PVS0402 = Socket Customer Advantages 4 For manual or automatic assembly Crimp Type Unit Packaging Cable Cross Section 01 = 1.5mm to 2.5mm 02 = 4.0mm to 6.0mm 4 Two piece design 4 Installation with a standard crimp tool Cable Outer Dimension 02 = 5.8mm up to 7.0mm (other diameters are being planned) 00* = Internal Style No. (determined by Yamaichi) For final part numbers please contact Yamaichi before odering in preparation in preparation Y-Sol4 C.A.T. Male Connector Y-Sol4 C.A.T. Female Connector Part 1 Part 1 Part 2 Part 2 Assembled For Specifications please refer to table on next page Assembled Y-Sol4 Free Assembly Connector (F.A.T.) The Y-Sol4 F.A.T. (Free Assembly Type) is a connector for fast and safe field installation. The connector comes in male and female types and has only two parts to connect with the cable. The assembly is closed by simply screwing the two parts together. There are absolutely no tools for this operation required. Tool Free Y-Sol4 F.A.T. Part Number (example) and various combinations O 4mm contacts - spring type assembly Customer Advantages PVP0402 - 202 - 02 02 - 00* Series No. for Free Assembly Type PVP0402 = Plug PVS0402 = Socket Spring Type Unit Packaging 4 No tool required Cable Cross Section 01 = 1.5mm to 2.5mm 02 = 4.0mm to 6.0mm 4 Two piece design 4 Installation in just three steps Cable Outer Dimension 02 = 5.8mm up to 7.0mm (other diameters are being planned) 00* = Internal Style No. (determined by Yamaichi) For final part numbers please contact Yamaichi before odering in preparation in preparation Y-Sol4 F.A.T. Male Connector Y-Sol4 F.A.T. Female Connector Part 1 Part 2 Part 1 Part 2 Assembled Assembled W E N Assembly Process Spring Contact Step 1 Step 2 Insert cable to contact. Close spring to hold cable Insert contact to housing in the direction of the arrow Step 3 Tighten screw cap spring Specifications Description Y-SOL4 F.A.T. / Y-SOL4 C.A.T. Diameter 18.8mm Degree of protection IP67 Protection class II Cable cross section 1.5mm to 2.5mm and 4.0mm to 6.0mm Cable outer diameter 5.8mm to 7.0mm (other dimensions are planned) Ambient temperature -40C to +85C Contact resistance < 5m (typ. value 1m up to 3m) Voltage rating 1,000 V DC acc. to TUV EN50521 Current rating 30A (based on 4mm cross section) Extraction force > 89 Newton 600 V DC acc. to UL 1703 TF J-Box for Thin Film Modules The Y-Sol(R) Thin Film J-Box can be easily assembled either manually or in an automatic assembly process. Contacting to the PV module is realised by spring loaded contacts in the J-Box lid. One bypass diode can be integrated optionally as per customer requirements. 100% controlled quality by Yamaichi. Junction Boxes TF J-Box Special Features Spring loaded contacts Double sided adhesive Customer Advantages No tools required Easy and safe contact assembly Simple mounting to module Part Number (example) and various combinations Y-SOL4B TFL 1 2 1U M06 F08 GM* Series No. for Overmolded (Hermetic Sealed) TFS = Short Type TFL = Long Type 0 = No Bypass Diode 1 = With Bypass Diode Two Spring Contacts Cable Cross Section 1U = 1.5mm, with TUV and UL 2U = 2.5mm, with TUV and UL M06 = Male Cable (e.g. 06 = 0.6 meter) F08 = Female Cable (e.g. 08 = 0.8 meter) GM* = Internal Style No. (determined by Yamaichi) Certified: acc. to EN50521 (TUV) acc. to UL 1703 For final part numbers please contact Yamaichi before odering Specifications Description TF J-Box Dimensions (L x W x H) in mm Short Type: 60 x 70 x 12 Degree of protection IP65 Protection class II Number of diodes Optional with one bypass diode Number of ribbons 2 Ribbon width max. 10mm Conductor cross section 1.5mm and 2.5mm Voltage rating 1,000 V DC acc. to TUV EN50521 Current rating up to 7A depending on J-Box configuration Long Type: 68 x 70 x 12 600 V DC acc. to UL 1703 Universal J-Box for Silicon Wafer Modules Featuring SMD diode technology, the Y-Sol(R) Universal J-Box shows approx. 40% less heat development compared to J-Boxes with conventional radial diodes. Automated assembly in an assembly line is possible, either by spring or soldering connection. It is one of the flatest Silicon Wafer J-Boxes on the market (<27mm height) and features integrated cable holders. 100% controlled quality by Yamaichi. Universal J-Box Special Feature SMD Diode Customer Advantages In case of a short-cut there is 40% less heat in the PV junction box This means more saftey in operation Part Number (example) and various combinations Y-SOL4B SI 3 4 C 1 4T M10 F8 GM* Series No. Y-SOL3B with Y-Sol3 Y-SOL4B with Y-Sol4 Si Wafer J-Box Number of Bypass Diodes (3 is standard) Number of Contacts/Rails C = Clamped Contacts S = Solder Contacts 1 = PCB Standard Type 2 = Non Ribbon Crossing Type Cable Cross Section 4T = 4.0mm, with TUV 6T = 6.0mm, with TUV M10 = Male Cable overall Length (e.g. 10 = 1 meter) Certified: acc. to EN50521 (TUV) F8 = Female Cable overall Length (e.g. 8 = 0.8 meter) GM* = Internal Style No. (determined by Yamaichi) Specifications For final part numbers please contact Yamaichi before odering Description Universal J-Box Dimensions (LxWxH) 111 x 140 x 26.5 Degree of protection IP67 Protection class II Number of diodes Optional with up to 6 bypass diodes Number of ribbons 2-8 Ribbon width max. 7.5mm Conductor cross section 4.0mm and 6.0mm Voltage rating 1,000 V DC acc. to TUV EN50521 Current rating up to 20A depending on J-Box configuration New Innovative Products n o o S g Comin The Eco-Si Junction Box Reduced to the Optimum Yamaichi Eco-Si J-Box for Silicon Wafer Modules 4 Mechanical Rating: IP67 4 Number of Diodes: up to 3 bypass diodes 4 Number of Ribbons: up to 4 4 Voltage Rating: 1,000V DC 4 Current Rating: 12A 4 For welding or soldering connection 4 Ready equipped with Y-Sol3 or Y-Sol4 connector The cost effective solution for Silicon Wafer Modules with up to 3 bypass diodes The Intelligent Junction Box Silicon is a Semiconductor. It is conductive under light. It becomes non conductive when shadowed. In the case of partial shadowing on a PV panel, the affected cell area must be controlled by the Junction Box 4 Intelligent System Power Control on module level 4 Wireless Communication 4 Power Organisation by a transistor controlled J-Box with Maximum Power Point (MPP) tracking on module level 4 Monitoring and Control Intelligent J-Box For further information please contact Yamaichi YAMAICHI ELECTRONICS USA Inc. 475 Holger Way San Jose, CA 95134 Sales Office Tel: 1-408-715-9100 Fax: 1-408-715-9199 e-mail: info@yeu.com Internet: www.yeu.com PV panel performance data send to Active Combiner Wireless Active Combiner sends on data to PC Monitoring and Control using a PC environment for isolating problems YAMAICHI ELECTRONICS Deutschland GmbH Karl-Schmid-Str. 9 81829 Munich Germany Tel.: +49 (0) 89 45 10 9 - 0 Fax: +49 (0) 89 45 10 9 - 110 e-mail: sales@yamaichi.de Internet: www.yamaichi.eu Aug 2010 Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: Yamaichi Electronics: Y-SOL4BOX-U003P-0 PVS0402-202-0202-000 Y-SOL4BOX-U004S-0 Y-SOL4BOX-U004P-0 Y-SOL4BOX-U003S-0 PVP0402-202-0202-000