Instruction Sheet SOLARLOK* Stamped and Formed Contacts and Connectors 408-- 10286 14 DEC 09 Rev B Cable Screw Joint Pinch Ring Plug Connector Assembly 1740940 Seal Socket Contact 2058454 or 2106356 Socket Housing Pin Housing Pin Contact 2058453 or 2106355 Seal Receptacle Connector Assembly 1740939 Pinch Ring Cable Screw Joint Figure 1 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 NOTE i 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. CAUTION ! This connector must be used only to interconnect firmly fixed cables. Do NOT disconnect under load. DANGER To protect against shock, ensure that conductors and their associated connectors are separated from opposite polarity components. CAUTION 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 S Use only UL/TUV rated photovoltaic cable (see Figure 9 for approved cables). S Pre--assembled connectors are for wire insulation diameters 4.5--6.9 mm. Insert wire with contact directly into the pre--assembled connector. See Figure 7. All other wire insulation sizes follow instruction Steps 3 thru 5. S Alternative seals for varying wire insulation sizes are provided in Figure 2. TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111 E2009 Tyco Electronics Corporation, Harrisburg, PA PRODUCT INFORMATION 1-- 800-- 522-- 6752 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. This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at www.tycoelectronics.com 1 of 4 LOC B 408- 10286 SOLARLOK Stamped and Formed Contacts and Connectors 3. Assemble the pinch ring (see Figure 5) before inserting contact if the connector is not preassembled. S The cable seal should be selected based upon the insulation diameter of the wire being used. S The cable seal and pinch ring must be matched to the cable diameter. SEAL INNER DIA. 5 mm INSULATION DIA. RANGE 4.2--5.3 mm CABLE SEAL 1394465--1 PINCH RING 1418677--1 6 mm 5.3--6.2 mm 1394465--2 1418677--1 7 mm 8 mm 6.2--7.2 mm 7.2--8.0 mm 1394465--3 1394465--4 1418677--2 1418677--2 Pinch Ring Figure 5 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 2 3.2. Contact Repair/Replacement CAUTION ! 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. Contact Locked in Place A. Assembly Steps Housing 1. Place backshell nut onto wire as shown in Figure 3. Backshell Nut Figure 6 NOTE i 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. Insert Into Pre-- Assembled Connector Figure 3 2. Press seal into the connector housing until it stops as shown in Figure 4. Seal Inserted Seal Figure 7 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. Backshell Nut Tightened on Connector Housing Label Figure 4 2 of 4 Figure 8 Tyco Electronics Corporation Rev B 408- 10286 SOLARLOK Stamped and Formed Contacts and Connectors CABLE TYPE TIGHTENING TORQUE TIGHTENING TORQUE (PRE-- ASSEMBLED CONNECTORS) Tyco Electronics UL/TUV Dual--Rated PV Cable Okonite USE--2 14, 12, and 10 AWG Tyco Electronics Wire 14, 12, and 10 AWG 0.8 +0.1 Nm [7.1 +.8 lb--in.] 0.8 +0.1 Nm [7.1 +.8 lb--in.] 1.3 +0.2 Nm [11.5 +1.7 lb--in.] 1.3 +0.2 Nm [11.5 +1.7 lb--in.] 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 Huber & Suhner 6.0 mm2 and 10 AWG 0.8 +0.1 Nm [7.1 +.8 lb--in.] 0.8 +0.1 Nm [7.1 +.8 lb--in.] 1.3 +0.2 Nm [11.5 +1.7 lb--in.] 1.3 +0.2 Nm [11.5 +1.7 lb--in.] Figure 9 B. Connector Mating NOTE i A 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. Positive Marking PLUS + B MINUS - Figure 11 When mating the SOLARLOK Connector System, the following must be ensured: Negative Marking S The plus-- and minus--coded connectors can only be mated to a similarly coded connector. S The connector system is fully latched only when the latches are flush with the mating connector. 3.3. Connector Unmating CAUTION ! Figure 10 CAUTION ! Cable assemblies should be labeled using Tyco Electronics label 1718077--1. 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. Rev B Do NOT disconnect connectors under load. Disconnect circuit from load before unplugging connectors. To unmate the connector: S The locking mechanism is opened by depressing the latches as shown in Figure 12. S While depressing the latches, disconnect the plug by pulling the connector halves apart. 4. REVISION SUMMARY S Updated document to corporate requirements S Added information in Figures 1 and 9 and new Paragraph 3.2 and renumbered Tyco Electronics Corporation 3 of 4 408- 10286 SOLARLOK Stamped and Formed Contacts and Connectors Pull Apart Depress Locking Latches Figure 12 4 of 4 Tyco Electronics Corporation Rev B