1394462-4 - Tyco Electronics

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

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

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

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

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

CAUTION

408- 10286

SOLARLOK Stamped and Formed Contacts and Connectors

Rev B4 of 4 Tyco Electronics Corporation

Figure 12

Depress Locking Latches Pull Apart