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Application Specification 114-106078

Jul 11

, 2013 Rev. C1

This specification is a controlled document. Page 1 of 12

SOLARLOK PV4 Connector

CONTENT

1 Introduction ............................................................................................................................ 2

2 Supporting Document ........................................................................................................... 2

2.1 Drawings ........................................................................................................................... 2

2.2 Document ......................................................................................................................... 2

3 Requirements ......................................................................................................................... 3

3.1 General Instructions ........................................................................................................ 3

3.2 Termination of the cable wires / crimping of the contacts ........................................... 4

3.2.1 Handling Of Connectors and Cables ........................................................................ 4

3.2.2 Assembly and Connection of Wire Leads ................................................................ 4

3.2.3 Crimping Tooling ....................................................................................................... 6

3.3 Assembly of Connectors ................................................................................................. 7

3.3.1 Selection of Sealing & Pinch Ring for Connectors ................................................. 7

3.3.2 Assembly of the connectors ..................................................................................... 7

3.4 Connectors Mating ........................................................................................................... 9

3.5 Disconnecting .................................................................................................................. 9

3.6 Protective Cover for connectors ................................................................................... 11

4 Applications Examples ........................................................................................................ 11

5 Storage .................................................................................................................................. 11

6 Tools ..................................................................................................................................... 12

Summary of content (12 pages)

PAGE 1
Application Specification 114-106078 Jul 11th, 2013 Rev. C1 SOLARLOK PV4 Connector CONTENT 1 2 Introduction ............................................................................................................................ 2 Supporting Document ........................................................................................................... 2 2.1 Drawings ........................................................................................................................... 2 2.
PAGE 2
Application Specification 114-106078 Jul 11th, 2013 Rev. C1 1 Introduction This specification covers the requirements for application of the SOLARLOK PV4 Connector as well as guideline for the assembly. Figure 1 When corresponding with TE connectivity personal, use the terminology in this specification to facilitate your inquiries for information. Basic terms and features of this product are provided in Figure 1. 2 Supporting Document 2.
PAGE 3
Application Specification 114-106078 Jul 11th, 2013 Rev. C1 TE internal test report: 501-106078 TUV cert. reference document: EN 50521 3 Requirements Do NOT disconnect under load! Current path should only be disconnected using approved disconnect devices.
PAGE 4
Application Specification 114-106078 Jul 11th, 2013 Rev. C1 Unconnected connectors must always be protected from pollution (e.g.dust humidity, foreign particles, etc), prior to installation. Do NOT leave unconnected (unprotected) connectors exposed to the environment.. 3.2 Termination of the cable wires / crimping of the contacts Connectors use different crimp contacts for various wire gauges. It is necessary to use the proper tool for wire gauge size. Possible connectable wire gauges sizes are 4.
PAGE 5
Application Specification 114-106078 Jul 11th, 2013 Rev. C1 Nominal Wire Size (mm2 / AWG) 4.0 / 12 6.0 / 10 Wire Strip Length (mm) 6.5+1.0/-0.5 6.5+1.0/-0.5 Table 1 2) Crimping Contacts Making the crimping contacts connection with suitable cross-section tooling and crimped according to the instructions packaged with the tooling. See section 3.2.3, Crimping Tooling, of this document for detail on tooling options.
PAGE 6
Application Specification 114-106078 Jul 11th, 2013 Rev. C1 B. Effective Crimp Length For optimum crimp effectiveness, the crimp must be within the area shown in Figure 4 and must meet the crimp dimensions provided in Table 2. C. Wire-End Protrusion Length The wire barrel shall not exceed the dimension shown in Figure 4 and Table 2. D. Wire Location The wire conductor must be visible in the transition area between the wire barrel and insulation as shown in Figure 4. E.
PAGE 7
Application Specification 114-106078 Jul 11th, 2013 Rev. C1 3.3 Assembly of Connectors 3.3.1 Selection of Sealing & Pinch Ring for Connectors The connector should select a suitable sealing & pinch ring for assembly according to the outside diameter of the cable. Pinch Ring selection criterion: Suppose the general tolerance is ±0.2mm max. of cable Outside Diameter (OD), if norminal OD of cable is less than or equal 6.0mm, 1740379-2 is preferred, if norminal OD of cable is bigger than 6.
PAGE 8
Application Specification 114-106078 Jul 11th, 2013 Rev. C1 Figure 6 Preassembled Sealing & Pinch ring 2) Connect the cable screw joint nut on to the connector housing (only 2-3 turns). Figure 7 Preassembled Connector Housing 3) Insert the contact crimped wire lead of cable until an audible click sound is heard and then give a slight pull back (a maximum of 5~10N force) to check whether the contact is locked. a) The contact engagement force is max.
PAGE 9
Application Specification 114-106078 Jul 11th, 2013 Rev. C1 3.4 Connectors Mating When mating the connectors, ensure the following;  It is only allowed to connect a plus (+) coded connector to a minus (-) coded connector. Connectors with identical polarity mark are not allowed to couple (forbidden to use + on + or on -)  Mating of the connectors is done by pushing the connectors together until a clear audible click is heard.
PAGE 10
Application Specification 114-106078 Jul 11th, 2013 Rev. C1 Figure 12 Hand Application Tool 1. The locking mechanism is opened by depressing the latches with hand application tool (PN 1971903-1) as shown in Figure 13. 2. Disconnect the connectors connection while the special tool insertion into the locking mechanism to depress the latches, and pull the connectors apart. Figure 13 Disconnect the connectors 3.
PAGE 11
Application Specification 114-106078 Jul 11th, 2013 Rev. C1 3.6 Protective Cover for connectors These protective dust caps serve for the protection against environmental contaminants. Figure 15 4 Applications Examples PV module Serial connection example Figure 16 5 Storage See Product specification 108-106078. This specification is a controlled document.
PAGE 12
Application Specification 114-106078 Jul 11th, 2013 Rev. C1 6 Tools 1. The following tools are available for crimping the contacts including hand crimping tool (PN 61579014-8) and crimp head (PN 4-1579016-7) 2. Insulation stripper (PN 4-1579002-2) is recommended for stripping the wire. 3. Hand application tool (PN 1971903-1) is available for assembling and disconnecting the connectors. 4.