Instruction Sheet
SOLARLOK* Stamped
and Formed Contacts 408--10286
LOC B
1of 4
E2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTER 1--800--722--1111
PRODUCT INFORMATION 1--800--522--6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
14 DEC 09 Rev Band Connectors
Figure 1
Receptacle Connector
Assembly 1740939
Plug Connector
Assembly 1740940
Socket Housing
Socket Contact
2058454 or
2106356
Seal
Pinch Ring
Cable Screw Joint
Cable Screw Joint
Pinch Ring
Pin Contact
2058453 or
2106355
Pin Housing
Seal
1. INTRODUCTION
This instruction sheet provides assembly procedures
for the SOLARLOK Stamped and Formed Contacts
and Connectors. These contacts are to be used as
alternatives to standard screw--machined HVT
contacts currently used in photovoltaic products. The
contacts are a drop--in replacement and can be
directly assembled into existing SOLARLOK
Connectors. See Figure 1.
2. DESCRIPTION
The contacts are made from copper alloy and are
silver over nickel plate with a wire size range of
2.5--6.0 mm2[14--10 AWG]. The SOLARLOK
contacts will mate with existing screw--machined
SOLARLOK contacts and will fit into existing
SOLARLOK connector housings.
3. ASSEMBLY PROCEDURES
Refer to Instruction Sheet 408--10322 for
termination of the contacts and Application
Specification 114--13256 for application
requirements of the SOLARLOK Contacts and
Connectors. Assembly procedures show pin
contact and connector, but socket contact and
connector is assembled similarly.
This connector must be used only to interconnect
firmly fixed cables. Do NOT disconnect under
load.
To protect against shock, ensure that conductors
and their associated connectors are separated
from opposite polarity components.
Any kind of pollution (dust, humidity, etc.) during
the assembly process can degrade contact and
connector performance. This applies in particular
to the seals and the crimping of the contacts. A
clean assembly environment is therefore
essential.
3.1. Selection of Cable Seal and Pinch Ring for Cable
Connectors
SUse only UL/TÜV rated photovoltaic cable (see
Figure 9 for approved cables).
SPre--assembled connectors are for wire insula-
tion diameters 4.5--6.9 mm. Insert wire with
contact directly into the pre--assembled con-
nector. See Figure 7. All other wire insulation
sizes follow instruction Steps 3 thru 5.
SAlternative seals for varying wire insulation
sizes are provided in Figure 2.
NOTE
i
CAUTION
!
DANGER
CAUTION
!
408- 10286
SOLARLOK Stamped and Formed Contacts and Connectors
Rev B2 of 4 Tyco Electronics Corporation
SThe cable seal should be selected based upon
the insulation diameter of the wire being used.
SThe cable seal and pinch ring must be matched
to the cable diameter.
SEAL
INNER DIA.
INSULATION
DIA. RANGE
CABLE
SEAL
PINCH
RING
5mm 4.2--5.3 mm 1394465--1 1418677--1
6mm 5.3--6.2 mm 1394465--2 1418677--1
7mm 6.2--7.2 mm 1394465--3 1418677--2
8mm 7.2--8.0 mm 1394465--4 1418677--2
Figure 2
3.2. Contact Repair/Replacement
SOLARLOK Stamped and Formed Contacts are
not to be re--inserted into a SOLARLOK housing
after extraction. A new contact must be applied to
the cable.
A. Assembly Steps
1. Place backshell nut onto wire as shown in
Figure 3.
Figure 3
Backshell Nut
2. Press seal into the connector housing until it
stops as shown in Figure 4.
Figure 4
Seal
Inserted Seal
3. Assemble the pinch ring (see Figure 5)
before inserting contact if the connector is not
preassembled.
Figure 5
Pinch Ring
4. Push contact with cable into the connector
housing until you hear the contact click into
plastic housing; pull back to ensure the contact
is locked. See Figure 6.
Figure 6
Contact Locked in Place
Housing
For pre--assembled connectors, insert contact as
shown in Figure 7, until you hear the contact click
into plastic housing; pull back to ensure the
contact is locked.
Figure 7
Insert Into Pre--Assembled Connector
5. Screw backshell nut onto connector housing.
See Figure 8. Tighten backshell nut to a torque
(maximum: 1.5 Nm [13.3 lb--in.]) dependent on
wire insulation diameter. See Figure 9 for
specific tightening torque value based on wire
insulation diameter. Identify plug connector with
label reading “DO NOT DISCONNECT UNDER
LOAD” as shown in Figure 8.
Figure 8
Backshell Nut Tightened on Connector Housing
Label
CAUTION
!
NOTE
i
408- 10286
SOLARLOK Stamped and Formed Contacts and Connectors
3of 4Rev BTyco Electronics Corporation
CABLE TYPE TIGHTENING TORQUE TIGHTENING TORQUE
(PRE--ASSEMBLED CONNECTORS)
Tyco Electronics UL/TÜV Dual--Rated PV Cable 0.8 +0.1 Nm [7.1 +.8 lb--in.] 1.3 +0.2 Nm [11.5 +1.7 lb--in.]
Okonite USE--2 14, 12, and 10 AWG 0.8 +0.1 Nm [7.1 +.8 lb--in.] 1.3 +0.2 Nm [11.5 +1.7 lb--in.]
Tyco Electronics Wire 14, 12, and 10 AWG 1.3 +0.2 Nm [11.5 +1.7 lb--in.] 1.3 +0.2 Nm [11.5 +1.7 lb--in.]
Studer Cable Betaflam 125 12 and 10 AWG 0.8 +0.1 Nm [7.1 +.8 lb--in.] 1.3 +0.2 Nm [11.5 +1.7 lb--in.]
Huber & Suhner 6.0 mm2and 10 AWG 0.8 +0.1 Nm [7.1 +.8 lb--in.] 1.3 +0.2 Nm [11.5 +1.7 lb--in.]
Figure 9
B. Connector Mating
When mating the SOLARLOK Connectors,
ensure that connectors labeled with a “+” or “--”
are keyed and can only be mated to similarly
marked and keyed connectors. See Figure 10.
Figure 10
Positive Marking
Negative Marking
The “neutral” designated receptacle--connectors
incorporate no keying features and may be freely
mated to either “+” or “--” keyed plug--connectors.
The neutral product should not be used where
maintaining polarity is critical. It is only permitted
for serial connections.
The polarity of a “neutral” connector must be
labeled with (1394725--1 or --2) nearby the
connector. See Figure 11.
Figure 11
PLUS
+
MINUS
-
A
B
When mating the SOLARLOK Connector
System, the following must be ensured:
SThe plus-- and minus--coded connectors can
only be mated to a similarly coded connector.
SThe connector system is fully latched only
when the latches are flush with the mating con-
nector.
3.3. Connector Unmating
Do NOT disconnect connectors under load.
Disconnect circuit from load before unplugging
connectors.
Cable assemblies should be labeled using Tyco
Electronics label 1718077--1.
To unmate the connector:
SThe locking mechanism is opened by depress-
ing the latches as shown in Figure 12.
SWhile depressing the latches, disconnect the
plug by pulling the connector halves apart.
4. REVISION SUMMARY
SUpdated document to corporate requirements
SAdded information in Figures 1 and 9 and new
Paragraph 3.2 and renumbered
NOTE
i
CAUTION
!
CAUTION
!
408- 10286
SOLARLOK Stamped and Formed Contacts and Connectors
Rev B4 of 4 Tyco Electronics Corporation
Figure 12
Depress Locking Latches Pull Apart
