SOLARLOK
Connectivity Systems for PV Installers
TE Connectivity is committed to bringing the promise of
renewable energy to the world. The SOLARLOK product oering
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.
Building a greener tomorrow
With approximately 7,000 engineers and 11 global design centers,
plus manufacturing facilities in approximately 25 countries, we put
a premium on innovation when it comes to helping companies solve
tough design problems. Talking to us early on in your design cycle
will give you the full benefit of our expertise.
We can help you:
Shorten the design cycle
Reduce costs
Increase reliability
Design for manufacturability
In short, we can help you achieve a sustainable competitive
advantage. Whether it’s showing you the best existing products,
oering a value added solution or designing a new product,
our commitment to advanced engineering and world-class
manufacturing delivers innovation that can advance any solar
project. Our Electronic Components segment is a world leader
in passive electronic components, including connectors and
interconnect systems, relays, switches, circuit protection devices,
touchscreens, sensors, and wire and cable. TE’s ability to serve
your present and future requirements is realized through the
synergies of a strong R&D program and our expertise in materials
science, product design and process engineering, all supported by
our network of 5000-plus knowledgeable, sales representatives
and customer service personnel.
Early involvement pays
o in competition advantage
TE Global Design Centers
1 : Harrisburg, PA : USA
2 : Greensboro/Winston-Salem, NC : USA
3 : Menlo Park, CA : USA
4 : Wilsonville, OR : USA
5 : Eatontown, NJ : USA
6 : Kawasaki, Japan
7 : Bensheim, Germany
8 : Shanghai, China
9 : Kessel-Lo, Belgium
10 : s’Hertogenbosch, Netherlands
11 : Kyungsan, Korea
Solar Manufacturing Facilities
A : Trutnov, Czech Republic
B : Greensboro, NC : USA
C : Empalme, Mexico
D : Hermosilla, Mexico
E : DongGuann, China
F : Shanghai, China
G : QingDao, China
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
2
Mechanical, Environmental and Electrical Testing Capabilities
Force-deflection curves are generated to verify that
spring contact properties meet design criteria.
3D X-ray computer tomography provides high
resolution three-dimensional non-destructive
analysis capability.
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.
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
3
Manufacturing Capabilities
The Trutnov, Czech Republic facility offers a repeatable manufacturing process which
produces a 100% automatically inspected and electrically tested junction box. For quality
control purposes, each junction jox is “laser etched” with a unique serial number.
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
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
TE manufactures the
SOLARLOK product
line on state of the
art manufacturing
equipment.
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
4
The SOLARLOK Product Concept
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
•Wide temperature operating range
•TÜV and UL approved
Solar Cable
•Dual wall insulation
•Electron beam cross-linked
•Excellent resistance to U.V., water,
ozone, fluids, salt, general weathering
•Excellent resistance to abrasion
•Halogen free, flame retardant, low toxicity
•Very low smoke emissions
•Excellent flexibility and stripping performance
•Temperature Rating : –40°C up to +125°C
•Nominal Voltage : Vo/V 1800/3000 VAC,
2600 VDC
•Test Voltage : 6KV, 50Hz, 5min
•Bending Radius : ≥ 5 x outer diameter
•TÜV and UL approved
System Features
Market expansion of the formerly regulated
energy supply sector, increased global
environmental awareness and governments
committing themselves to more stringent
environmental targets have opened up new
opportunities for the photovoltaic industry.
Having served a niche market in the past, the
photovoltaics industry now has the opportunity
to move into mass production, realizing
economies of scale and gaining a greater
market share of the world’s energy mix.
TE has contributed to the establishment of this
environmentally-friendly tech nology with the
introduction of its SOLARLOK connector system.
The SOLARLOK connector system delivers a
flexible system solution for easy and reliable
interconnections from photovoltaic modules to
the DC/AC converter. The entire system concept
is based on cost-effective and reli able processing
of individual interconnection system components.
This significantly reduces installation costs of
the solar energy system.
The junction box concept is based on a flexible,
open system structure, which allows serial as well
as parallel interconnection via direct wire connect
or separable connectors. Within the junc tion box,
up to six termination places rails are available for
photovoltaic foil connection. If required by the
customer, the junction box can be delivered
pre-configured with diodes, jumpers, plug
connectors, and solar cable pigtails.
The male and female cable couplers were
designed for high voltage and high current-
carrying capa city in addition to the well-
established IP 67 sealing require ment in the
photovoltaic industry. Mating safety is provided
by polarity keyed housings, fully shrouded
contacts, reliable high cycle life, and a squeeze
to release connection system. In addition, a wide
temperature range and fulfill ment of worldwide
standards for photovoltaic connection systems
complement the robust product specification.
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
5
Table of Contents
Combiner Box ........................................................................................................................page : 8
Transition Box ...................................................................................................................... page : 9
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 ..................................................................................................................................... page : 15
Solar Cables ....................................................................................................................page : 16-17
Wiring Example with Extension Cables .................................................................... page : 18
Grounding System : Grounding Bolt ...........................................................................page : 19
Grounding System : Grounding Clip ..........................................................................page : 20
Interconnection Examples .......................................................................................page : 22-23
Application Tooling ................................................................................................... page : 24-25
Assembly and Installation Guidelines ................................................................ page : 26-29
Numerical Index ...........................................................................................................page : 30-31
Combiner Box
Connectors
Labels
Solar Cables
Grounding System
Connectors
Tooling
Guidelines
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
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
8
5-String Combiner Box
•Combines up to 5 PV strings
•Converts to standard wires
•Completely pre-assembled
•Plug & play design provides labor
savings and minimizes installer
error during installation
•Uses existing products currently
produced by Tyco Electronics
•UL 1741 listed
Features & Benefits
Technical Data
The SOLARLOK combiner box assembly is used to combine up to five strings in a
preterminated connectorized weather-resistant enclosure to meet National Electric Code
(NEC) requirements for series fusing of photovoltaic (PV) modules (solar panels).
The combiner box assembly consists of a box, cover (with hinges), transparent dead front
lid (under the cover), and 10 pre-terminated SOLARLOK connectors each with a removable
dust cover. The box features 4 knockouts (for output wiring), lock tab, mounting slots and
pre-wired grounding bolt.
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
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]
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
9
Transition Box
•Converts to standard wires
•Completely pre-assembled
•Plug & play design provides labor
savings and minimizes installer
error during installation
•Uses existing products currently
produced by TE
•UL 1741 listed
Features & Benefits
Technical Data
The SOLARLOK transition box is used to convert outdoor wire to more cost effective
building wire for use in protective conduit. The transition box assembly consists of a
pre-terminated connectorized weather-resistant enclosure to meet National Electric Code
(NEC) requirements, a cover (with hinges), a transparent dead front lid (under the cover),
and 10 pre-terminated SOLARLOK connectors, 5 pre-wired to the negative terminal
block and 5 pre-wired to the positive terminal block, each with a removable dust cover.
The box features 4 knockouts (for output wiring), a lock tab, mounting slots and a
pre-wired SOLARLOK grounding bolt.
Part Number : 2106916-1
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]
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
10
Cable Coupler : Standard Line
Technical Data
Technical Data
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
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
Female Cable Coupler (kit with screw-machined contact)
Gen 3 Seal Part Number Gen 2 Seal Part Number
Cable Outer Diameter
5.5 mm to 8.0 mm
Cable Outer Diameter
4.5 mm to 6.0 mm
Wire Size
Keying Package Quantitymm2AWG
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
5-1394462-6 6-1394462-4 6.0 10 Minus 100
Male Cable Coupler (kit with screw-machined contact)
Gen 3 Seal Part Number Gen 2 Seal Part Number
Cable Outer Diameter
5.5 mm to 8.0 mm
Cable Outer Diameter
4.5 mm to 6.0 mm
Wire Size
Keying Package Quantity
mm2AWG
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
6-1394461-6 7-1394461-4 6.0 10 Minus 100
6-1394461-1 6-1394461-3 2.5 14 Neutral 100
6-1394461-2 7-1394461-2 4.0 12 Neutral 100
6-1394461-4 7-1394461-5 6.0 10 Neutral 100
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
11
Cable Coupler : Slim Line
Male Cable Coupler (kit with screw-machined contact)
Part Number Wire Size Keying Package Quantity
mm2AWG
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
Male Cable Coupler (without contact : only housing and sealing)
Part Number Wire Size Keying Package Quantity
mm2AWG
1987286-4 -- -- Plus 2,500
1987286-5 -- -- Minus 2,500
1987286-6 -- -- Neutral 2,500
Female Cable Coupler (kit with screw-machined contact)
Part Number Wire Size Keying Package Quantity
mm2AWG
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)
Part Number Wire Size Keying Package Quantity
mm2AWG
1987287-1 -- -- Plus 2,500
1987287-2 -- -- Minus 2,500
Technical Data
Technical Data
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 pending
TÜV approved
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 pending
TÜV approved
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
12
Replacement Contacts
Male Contacts (Screw-Machined)
Material : Copper alloy, silver plated
Part Number Wire Size (mm2) 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
Technical Data Female Contacts (Screw-Machined)
Material : Copper alloy, silver plated
Part Number Wire Size (mm2) Wire Size (AWG) Package Quantity
1987281-1 2.5 AWG 14 100
1987281-2 4.0 AWG 12 100
1987281-3 6.0 AWG 10 100
24.5
4.1
Materials
Contact : Silver plated, copper alloy
Electrical Features
Current Rating
: Up to 25 A
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
13
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
2106207-1* NEC 2008/USA UTE C15-712/
France 100
*Instruction Sheet : 408-10296
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
Female Housing : with strap Female Housing : no strap
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
14
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
Wire Size Range : 2.5 mm2 - 6.0 mm2
Standards
Approvals VDE Certified
AC Inverter Connector
Panel Mount Plug
Part Number Nut
Cable Length
(5 x 4.0 mm2)Package Quantity
1740483-1 Metal 200 mm 24
1740483-2 Plastic 200 mm 24
Complete Sets
Part Number Nut
Cable Length
(5 x 4.0 mm2)Package Quantity
1740493-1 Metal 200 mm 24
1740493-2 Plastic 200 mm 24
Free Hanging Receptacle
Part Number Nut
Cable Length
(5 x 4.0 mm2)Package Quantity
1740479-1 - - 24
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
15
Labels
Solar Identification Labels
Quantity/Roll TE Ordering Description SAP Part Number Label Description
5 rolls
of 100
SOL-SD-104076-4-0.1 CN4616-000 Solar Disconnect
SOL-DCD-104100-4-0.1 CN4619-000 DC Disconnect
SOL-DPS-104019-4-0.1 CN4618-000 Warning - Dual Power Sources
SOL-ESH-104019-4-0.1 CN4617-000 Warning - Electric Shock Hazard
500
SOL-SD-104076-4-0.5 CL3803-000 Solar Disconnect
SOL-DCD-104100-4-0. 5 CL3806-000 DC Disconnect
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
5 rolls
of 100
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
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
500
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
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
500 SOL-SEC-305254-4-0.1 CN6557-000 CAUTION : SOLAR ELECTRICAL SYSTEM
SOL-CSC-159254-4-0.1 CN4615-000 CAUTION : SOLAR CIRCUIT
Solar Label Print Kits : 300 dpi
SOL-PRINT-300 : PN 2-1878569-8
Kit Contents Description Part Number
T212M-PRINTER 300 dpi thermal transfer printer E23401-000
1330-0607-T200 Black resin thermal transfer ribbon E45478-000
PEP-5-PRO-DGLUSB Label printing software CC8954-000
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
PEP-5-PRO-DGLUSB Label printing software CC8954-000
Note :
Pre-print services are also available
for “peel and stick” application with
all pertinent electrical information.
Inquire with TE for further information
regarding this service.
(For Americas only)
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
16
As part of expanding the SOLARLOK product line, TE produces wire that is designed to meet
the harsh environmental conditions typical of photovoltaic installations. The flexible, dual wall,
halogen free and cross linked solar wire offers long term stability with TÜV UL approval.
Its outstanding features include: high resistance against environmental conditions such as
humidity, UV-radiation and ozone. In addition, it has excellent resistance to abrasion and
temperature extremes. The wire has a high dielectric withstanding voltage and due to its
fine-stranded, tin plated copper conductor, it is easy to handle, bend, route, and to strip.
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)
: 1800/3000 VAC
: 2600 VDC
Wire Size Range
: 2.5 mm2 (AWG 14)
: 4.0 mm2 (AWG 12)
: 6.0 mm2 (AWG 10)
Standards
TÜV certified according to 2PfG
1169/08.2007 (PV1-F) : RG0021060
UL certified according to UL Outline 4703
(PV wire, type ZKLA) : E317230
Fire Performance : IEC 60332-1-2, UL 1581
1080/VW1, EN 50267-2-1/2, EN 50305
Conductor : IEC 60228 class 5 (stranded
and flexible tin plated copper wire)
Global TÜV and UL 4703
Color Part Number
Cross Section Conductor
Diameter
(mm)
Weight
(kg/km)
Reel
Package
(m)
mm2AWG Construction
no. x mm
Max
Diameter
(mm)
Black
956297-4 2.5 14 50 x 0,26 1.95 6,65 +0,15/-0,1 62.5 500
956298-4 4.0 12 56 x 0,31 2.50 6,90 +/-0,10 75.8 500
956299-4 6.0 10 84 x 0,31 3.05 7,35 +0,3/-0,25 95.5 500
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
Red
956297-5 2.5 14 50 x 0,26 1.95 6,65 +0,15/-0,1 62.5 500
956298-5 4.0 12 56 x 0,31 2.50 6,90 +/-0,10 75.8 500
956299-5 6.0 10 84 x 0,31 3.05 7,35 +0,3/-0,25 95.5 500
1-956297-5 2.5 14 50 x 0,26 1.95 6,65 +0,15/-0,1 62.5 100
1-956298-5 4.0 12 56 x 0,31 2.50 6,90 +/-0,10 75.8 100
1-956299-5 6.0 10 84 x 0,31 3.05 7,35 +0,3/-0,25 95.5 100
Blue
956297-6 2.5 14 50 x 0,26 1.95 6,65 +0,15/-0,1 62.5 500
956298-6 4.0 12 56 x 0,31 2.50 6,90 +/-0,10 75.8 500
956299-6 6.0 10 84 x 0,31 3.05 7,35 +0,3/-0,25 95.5 500
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
•TÜV and UL approved
•Dual wall insulation
•Electron beam cross-linked
•Excellent resistance to abrasion
•Halogen free, flame retardant,
low toxicity
•Excellent flexibility and stripping
performance
•Wire size from 2.5 mm2 up to 6.0 mm2
Features & Benefits
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
17
USE-2 approved solar cable – for the North American market UL approved cable is offered
in 10 through 14 AWG. This cable is approved for USE-2, XHHW-2, RHW-2, or RHH. Sunlight,
gasoline, and petroleum resistance make this an ideal cable for any solar installation in
North America. A high strand count increases the flexibility and tinned copper wire strands
ease the use of this cable.
Type USE-2 (For US Installation), UL Approved Cable
Color Part Number Cross Section
AWG
Diameter
(inch)
Reel Package
(ft)
Black
1986166-1 14 0.17 7,500
1986166-2 14 0.17 500
1986166-3 14 0.17 2,500
1986165-1 12 0.19 7,500
1986165-2 12 0.19 500
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
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
•Insulation provides resistance
to U.V., water, ozone, fluids, salt,
gasoline, and petroleum general
weathering
•High strand count conductor
provides flexibility and
stripping performance
•Multiple cable diameters available
Features & Benefits
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
18
Wiring Example with Extension Cables
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.
Configuration Example at 4.0 mm2
Male Cable Coupler (+)
1394461-3 Female Cable Coupler (+)
1394462-3
Inverter
Female Cable Coupler (+)
1394462-3
Female Cable Coupler (+)
1394462-3
Male Cable Coupler (-)
1394461-4 Female Cable Coupler (-)
1394462-4
Female Cable Coupler (-)
1394462-4 Female Cable Coupler (-)
1394462-4
Female Cable Coupler (-)
1394462-4 Female Cable Coupler (+)
1394462-3
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
19
Grounding System : Grounding Bolt
Technical Data
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.
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)
: 8 AWG = 8lbs (30 minutes)
: 10 AWG = 5lbs (30 minutes)
: 12 AWG = 5lbs (30 minutes)
Pull out Test (ul 486A-B)
: 6 AWG = 100lbs (1 minute)
: 8 AWG = 90lbs (1 minute)
: 10 AWG = 80lbs (1 minute)
: 12 AWG = 70lbs (1 minute)
Application Tooling
Flex socket wrench or wrenches
Standards
UL 467 listed
UL File #E69905
A requirement for UL 1703
solar panel listing
CSA C22.2 No. 41-07
Part Number Description Thread Dim “A” Package Quantity
2058729-1 6-12 AWG #8-32 UNC .380 100
2106831-1 Long Shank 6-12 AWG #10-32 UNF .700 100
*Instruction Sheet : 408-10262
Product Oering
Dimensions
Top View Bottom ViewSide View
A
Edge Features
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
20
Features & Benefits
Technical Data
•Product comes as an assembled kit that
includes an attachment screw
•Contact design provides 4 points of
contact to the ground wire for high
reliability
•Product is easy to install with simple
tools that are readily available
•Removal of the installed ground wire
requires a screwdriver, this meeting the
tooled extration requirements
•RoHS compliant
Grounding System : Grounding Clip
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
copper wire.
12 AWG applications will withstand
70lbs pull while the 10 AWG
applications will withstand 80lbs pull
Application Tooling
No special tooling is required -- only
flathead screwdrivers and channel
lock pliers (optional)
Standards
Ul 467 listed
UL File #E69905
A requirement for UL 1703
solar panel listing
CSA C22.2 No. 41-07
Part Number Screw Nut Package Quantity Wire Size
1954381-1 #10-32 Thread Cutting None 100 10-12 AWG
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
1954381-4 #8-32 Long Shark none 100 10-12 AWG
1954381-5 #10-32 Thread Cutting none 100 6 mm2
*Instruction Sheet : 408-10160
Product Oering
... Ready... Push...Insert...
3 Easy Steps to Ground Your PV System
Dimensions
#8-32 Pan
Head Screw
24.5
16.8
94.5
32.5
10.0
#10-32 Thread
Cutting Screw
Closed Position
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
21
Engineering Notes
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
22
Serial Interconnection for Junction Boxes with Cable Glands
(4.0 mm2 / 12 AWG Wiring)
Interconnection Examples
DC/AC Converter
1394462-4 6-1394461-2
1394461-4 1394462-3
1394462-4 1394462-3
1394738-4 1394738-3
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
23
Serial Interconnection for Junction Boxes with Plug Connectors
(4.0 mm2 / 12 AWG Wiring)
Interconnection Examples (continued)
1394462-4 1394462-3
1394462-41394462-3
1394462-4 1394462-3
1394738-4 1394738-3
DC/AC Converter
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
24
Application Tooling
Hand Crimp Tool
for Screw Machine Contacts
Includes Crimp Head & Locator
PN : 1-1579004-1 (1.5 mm2 & 2.5 mm2)
: 1-1579004-2 (4.0 mm2 & 6.0 mm2)
Extraction Tool
(suitable for all wire sizes)
PN : 1102855-3
Insulator Stripper
Includes length stop for all wire size
(Suitable for our Solar Cable)
PN : 4-1579002-2 (1.5 mm2, 2.5 mm2,
4.0 mm2 and 6.0 mm2)
Cable Assembly
Tooling Specs
Base Machine : PN : 539630-1
Electrical Terminator CS 200
for Screw Machine Contacts
Adaptor for Crimp Head
PN : 1579000-4
Crimp Head
(1.5 mm2 and 2.5 mm2)
PN : 7-1579001-8
Crimp Head
(4.0 mm2 and 6.0 mm2)
PN : 7-1579001-9
Crimp Head (AWG 10)
PN : 8-1579001-2
Crimp Head (AWG 12)
PN : 5-1579001-5
SOLARLOK Electric
Terminator CS 200
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
25
Application Tooling (continued)
Junction Box
Assembly Tooling
Connector 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
Hexagon Spanner Head for
torque Wrench
PN : 523229-1
Torque Wrench,
PN : 2161345-1
•100 Cable Coupler
(Housings, Plus and Minus coded)
*Cable outer diameter 5.5 mm to 8.0 mm
•Crimp Contacts
(4.0 mm2 and 6.0 mm2)
•Pinch ring
•Seals
Part Number : 1534858-1
(Metric Wire)
Included in Kit:
Hand Crimp Tool
PN : 1-1579004-2
Extraction Tool
PN : 1102855-3
Insulation Stripper
PN : 4-1579002-2
Field Service Kit
•20 Cable Coupler
(Housings, Plus and Minus coded)
*Cable outer diameter 5.5 mm to 8.0 mm
•Crimp Contacts
(6.0 mm2)
•SOLARLOK Field Manual
•Instruction Sheets
Part Number : 5-1579010-4
Included in Kit:
Hand Crimp Tool
PN : 1-1579004-2
Extraction Tool
PN : 1102855-3
SOLARLOK INSTALLER
STARTER KIT
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
26
IMPORTANT NOTE
General Comments
Termination of the Cable
Wires and Crimping of
the Contacts
3.1 Handling
of the Connectors
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
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.
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.
•SOLARLOK connectors use different crimp contacts for various wire gauges.
•Possible wire gauges are 2.5 mm2, 4.0 mm2, and 6.0 mm2, AWG 14, AWG 12 and AWG 10.
•The tools to be used are selected based upon the wire gauge.
•For the application specification, please refer to specification #114-18488.
When assembling the connectors, the following sequence must be followed:
1 : Stripping the wire to 9 +/- 1mm without damaging the strands
(please refer to application specification #114-74013)
Fig.1
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
27
Assembly and Installation Guidelines (continued)
3.1 Handling of the
Connectors (continued) 2 : Insert the stripped wire into the wire crimp barrel until it stops.
3 : While holding the wire in place, squeeze tool handles together until ratchet releases.
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.
5 : Tighten backshell nut to 1.3 +0.2 Nm.
(For tooling, please refer to page 25, item 4)
Fig. 3
Fig. 2
Fig. 4
“CLICK”
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
28
Assembly and Installation Guidelines (continued)
3.2 Connector Latching
3.3 Disconnecting
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.
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.
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.
Fig. 6
Fig. 5
(female connector)
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
29
Assembly and Installation Guidelines (continued)
Application Examples
Storage
Tooling
See product specification 108-18701
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.
Fig. 7 : Serial (Wire Diagram) Fig. 8 : Parallel (Wire Diagram)
Technical Description
Fig. 9
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
30
PV Installers Numerical Index
Part Number Page
CN4615-000 15
CN6557-000 15
CN4616-000 15
CN4619-000 15
CN4618-000 15
CN4617-000 15
CN3803-000 15
CN3806-000 15
CN3804-000 15
CN3805-000 15
CR0780-000 15
CR0781-000 15
CR0782-000 15
CR0783-000 15
CR0784-000 15
CR0785-000 15
CR0786-000 15
CR0787-000 15
CR0788-000 15
CR0789-000 15
CR0791-000 15
CR0792-000 15
956297-4 16
956297-5 16
956297-6 16
1-956297-4 16
1-956297-5 16
1-956297-6 16
956298-4 16
956298-5 16
Part Number Page
956298-6 16
1-956298-4 16
1-956298-5 16
1-956298-6 16
956299-4 16
956299-5 16
956299-6 16
1-956299-4 16
1-956299-5 16
1-956299-6 16
1394461-4 10
1394461-7 10
1394461-8 10
6-1394461-1 10
6-1394461-2 10
6-1394461-3 10
6-1394461-4 10
6-1394461-5 10
6-1394461-6 10
7-1394461-0 10
7-1394461-1 10
7-1394461-2 10
7-1394461-3 10
7-1394461-4 10
7-1394461-5 10
4-1394462-6 10
1394462-1 10
1394462-2 10
1394462-3 10
1394462-4 10
Part Number Page
4-1394462-7 10
4-1394462-8 10
4-1394462-9 10
5-1394462-6 10
5-1394462-5 10
6-1394462-3 10
6-1394462-4 10
1394739-1 13
1534226-1 13
1534611-1 13
1534611-2 13
1740277-1 13
1740277-2 13
1740479-1 14
1740483-1 14
1740483-2 14
1740493-1 14
1740493-2 14
1-1740939-2 10
1-1740940-3 10
1-1740940-4 10
2-1878569-8 14
2-1878569-9 14
1954283-1 8
1954381-1 20
1954381-2 20
1954381-3 20
1954381-4 20
1954381-5 20
1986164-1 17
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
31
PV Installers Numerical Index (Continued) Tooling
Part Number Page
1986164-2 17
1986164-3 17
1986165-1 17
1986165-2 17
1986165-3 17
1986166-1 17
1986166-2 17
1986166-3 17
1987280-1 12
1987280-2 12
1987280-3 12
1987280-4 12
1987280-5 12
1987281-1 12
1987281-2 12
1987281-3 12
1987281-4 12
1987281-5 12
1987286-4 11
1987286-5 11
1987286-6 11
1987287-1 11
1987287-2 11
1987376-1 18
1987376-2 18
1987376-3 18
1987376-4 18
1987376-5 18
1-1987376-1 18
1-1987376-2 18
Part Number Page
2058729-1 19
2106207-1 13
2106916-1 9
2106831-1 19
1740969-1 25
523229-1 25
539630-1 24
1102855-3 24,25
1-1579004-1 24
1-1579004-2 24,25
1534858-1 25
1579000-4 24
8-1579001-2 24
5-1579001-5 24
7-1579001-8 24
7-1579001-9 24
4-1579002-2 24,25
1579007-2 25
1579007-3 25
1579007-5 25
5-1579010-4 25
1740969-2 25
1740969-3 25
2161345-1 25
Part Number Page
1-1987376-3 18
1-1987376-4 18
1-1987376-5 18
2-1987376-1 18
2-1987376-2 18
2-1987376-3 18
2-1987376-4 18
2-1987376-5 18
3-1987376-1 18
3-1987376-2 18
3-1987376-3 18
3-1987376-4 18
3-1987376-5 18
4-1987376-1 18
4-1987376-2 18
4-1987376-3 18
4-1987376-4 18
4-1987376-5 18
1987419-1 13
1987423-1 13
1987558-1 11
1987558-2 11
1987558-3 11
1-1987558-1 11
1-1987558-2 11
1-1987558-3 11
1987559-1 11
1987559-2 11
1-1987559-1 11
1-1987559-2 11
SOLARLOK Connectivity Systems for PV Installers
te.com/solar
Catalog 3-1773458-6 | Issue Date 04/2011
Dimensions are in inches and millimeters unless otherwise specified.
Values in brackets are standard equivalents. Dimensions are shown
for reference purposes only. Specifications subject to change.
USA: 1-800-522-6752 Latin/S. America: +54 (0) 11-4733-2200 France: +33 (0) 1-3420-8686
Canada: +1-905-475-6222 Germany: +49 (0) 6251-133-1999 Netherlands: +31 (0) 73-6246-999
Mexico: +52 (0) 55-1106-0800 UK: +44 (0) 800-267666 China: +86 (0) 400-820-6015
32
Engineering Notes
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
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© 2011 Tyco Electronics Corporation, a TE Connectivity Ltd. company. All Rights Reserved.
3-1773458-6 CIS FP 3M 04/2011
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are subject to change without notice. Consult TE for the latest dimensions and design specications.
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