Application Specification SOLARLOK* PV Edge

Application Specification SOLARLOK* PV Edge
Application Specification
SOLARLOK*
PV Edge Solar
Junction Box
114-32157
08 MAR 17 Rev E
NOTE
All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters. Unless
otherwise specified, dimensions have a tolerance of ±0.13 mm and angles have a tolerance of ±2°. Figures and illustrations
are for identification only and are not drawn to scale.
1. INTRODUCTION
This specification covers the requirements for application of SOLARLOK PV Edge Solar Junction Box onto a
photovoltaic (PC) solar panel. Each junction box consists of a base (with or without edge guides/flap tracks),
lid, plug connector cable assembly and socket connector cable assembly or no connector cable assembly for
connectorized versions.
The base features two open areas, two contact rails, and one diode. Each contact rail provides interface tabs
for terminating the foil tabs of the solar panel. The open areas allow foil tabs to reach the interface tabs while
maintaining a seal between the junction box and solar panel. Each diode features two legs that support it in
place on the contact rails. The back of the base features an attachment area used in mounting the junction box
onto the solar panel.
When corresponding with TE Connectivity Personnel, use the terminology provided in this specification to
facilitate your inquiries for information. Basic terms and features of this product are provided in Figure 1.
Glass-Glass Edge Mount Application
Vent
Edge Flap Track
“+” PV4
Interface
Latch
Solar Panel
(Typically Glass-Glass)
“+” End
Box
Edge Flap
“-” PV4
Interface
Center Box
Edge
Guide
“-” End Box
Figure 1 (cont’d)
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All Rights Reserved
*Trademark
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.te.com.
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.
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Traditional Mid-Panel Application
“+“ PV4 Interface
Solar Panel (Typically
Glass-Back Sheet)
Vent
Latch
“+“ End Box
Center Box
“-“ End Box
“-“ PV4 Interface
Figure 1 (end)
The lid features an O-ring that, when the lid is closed, ensures a tight seal. The lid has attachment tabs and a
latch. The latch ensures that the lid is locked and requires an instrument (such as a flat-blade screwdriver) to
release the latch.
NOTE
The application of the TE SOLARLOK PV Edge Solar Junction Box on the solar panel as well as the installation of the solar
panel is not part of the scope of services offered by TE. In addition, TE does not offer a warranty for the SOLARLOK PV Edge
Solar Junction Box with integrated solar cable assemblies if those cable assemblies will be exchanged or unfixed after delivery
from TE. A cable extension has to be made at the coupling end of the cable (plug connector) and only with TE components. If
single connectors without attached cable are delivered by TE, the mounting of the cable is also not in the scope of services
offered by TE. This is also the case for subsequent mounting or replacing diodes.
2. REFERENCE MATERIAL
2.1. Revision Summary
 Update section 3.8
2.2. Customer Assistance
Reference Product Base Part Numbers 2306314 (FLAP, S clip), 2306315 (No FLAP, S Clip), and Product Code
4013 are representative of the SOLARLOK PV Edge Solar Junction Box. Use of these numbers will identify the
product line and help you to obtain product and tooling information when visiting www.te.com or calling the
PRODUCT INFORMATION number at the bottom of page 1.
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2.3. Drawings
Customer drawings for product part numbers are available from www.te.com. Information contained in the
customer drawing takes priority.
2.4. Specifications
Product Specification 108-32122 provides approved product performance and test results for the SOLARLOK
PV Edge Solar Junction Box. Application Specification 114-137077 provides product description and
application requirements for PV4-S cables and connectors used with the junction box.
3. REQUIREMENTS
3.1. Safety
— Appropriate gloves and eye protection must be used throughout the entire installation of the junction
box.
— Adequate ventilation must be ensured at all times during the installation of the junction box.
— Eating, drinking, and smoking must not be allowed in the vicinity when installing or working with the
junction box.
— DO NOT expose the junction box to open flames.
3.2. Limitations
The junction box location and the installation and assembly procedures for the junction box, connectors, and
cable assemblies must agree with the ESD items.
—
—
—
—
—
—
Equip floor and workstation with ESD materials
Equip work tables by safety wrist and ankle straps.
Equip ESD shoes for every worker.
ESD tester in front of operation room door. Everyone who enters workshop should pass the ESD test.
Equip heel strip for visitors who do not wear ESD shoes.
Equip a tester to verify if wrist and ankle straps are well-grounded (every shift).
3.3. Storage
Product shipping containers must not be stacked so high that the containers buckle or deform. The product
should remain in the shipping containers until ready for use to prevent deformation to components. Junction
boxes, cable assemblies, and connectors must be stored in a clean, dry location.
3.4. PV Solar Panel
Before installing the junction box onto the solar panel, the following requirements apply:
1. The installation procedure described in this document may be used on either glass or glass with
plastic back sheet substrate solar panels.
2. The attachment area (located on the bottom) of the solar panel must be dry, oil-free, fat-free, and free
of any dust, and contaminants. The attachment area must be thoroughly cleaned using a soft cloth lightly
moistened (for example, by using a dosing unit) with isopropyl alcohol. Auxiliary and other cleaning agents
must be tested by the customer and proved suitable for use on the solar panel and junction box before
being used.
The attachment must be free of condensation and moisture.
Glass-Glass installation preparation: (edge mount, using boxes with edge flap and edge guide features TE
base p/n’s . 2306314 (FLAP, S clip).
The foil tabs extend from between the layers of glass and must be pre-formed, so they extend
perpendicular from the surface of the solar panel (See Figure 2).
Tedlar is a trademark.
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2A
Glass-Glass
Panel
2B
Glass-Glass
Panel
Foil
Foil
NOTE: See customer
drawings for recommended
foil length and shape when
junction box is edge-mounted
on glass-glass panels.
Figure 2
Glass-Back sheet installation preparation: (traditional mid-panel mounting, using boxes without the edge flap
and edge guide features TE base p/n’s . 2306315 (No FLAP, S Clip). Alternate option to use single hole in
back sheet or back glass to route both foils thru one 15mm diameter hole. See Figure 3.
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Glass-Back
Sheet Panel
Outline of Box
Final Location
Foil
NOTE: See customer drawings
for recommended foil length
when junction box is midmounted on glass-back sheet
panels.
Foil formed to
straddle under the
center of junction box
Foil
Foil terminated using
conventional methods
after box is installed
on panel.
Alternate Single Hole: Both foils exit
the back of the panel thru a single
15mm diameter hole. Note: customer
must insure the foil spacing meets
minimum creepage and clearance
distances for the panel application.
Figure 3
3.5. Connectors
The mating face of each connector must be protected from contaminants (such as moisture, dust, humidity,
environmental pollution, etc.). It is recommended that a suitable, such as TE part numbers 2232227-1 (socket)
and 2213228-1 (pin) dust cover be installed onto each unplugged connector. Connectors must be kept clean
and dry.
DANGER
To avoid personal injury by electric current, the junction box and connectors must be completely separate from other sources
of voltage during installation and assembly. The connectors must not be connected or disconnected when under electrical
load.
3.6. Installation
The following installation requirements are intended as a guideline.
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NOTE
All tools used for installation are covered in Section 5, TOOLING. Cleaning
Any type of exposure to contaminants (such as moisture, dust, humidity, environmental pollution, etc.) can
negatively affect function of the junction box over the duration of use. This especially applies to connector
seals and terminated connections. The environment of the area for installation and assembly must be
clean and dry.
In case of contamination, the junction box, cable assembly, and connectors should be cleaned using a
soft clean cloth moistened with isopropyl alcohol.
CAUTION
Cleaning products that can erode the plastic parts of the connectors and junction box must not be used. Oils or lubricants of
any type other than mentioned in this document must not be used on or around the junction box.
It is recommended that the mating face of each connector be protected by a suitable dust cover, such as
TE part numbers 2232227-1 (socket) and 2213228-1 (pin) until the connector is mated.
A. Mounting
1. TE junction boxes can be mounted with the connectors in any orientation when the solar panel is
expected to be operating under normal environmental conditions. To ensure the junction boxes and
connectors are fully protected from adverse environmental conditions, TE recommends that the junction
boxes are mounted to protect the connectors from damage due to environmental factors.
2. When applying the Silicone sealant or double sided adhesive tape to mount the junction box to the
solar panel, it is recommended that the junction box remains open and the junction box cover is not
attached.
NOTE
The referenced double-sided adhesive tape should be tested by the customer for suitability before using it on solar panels that
are not entirely flat. The double-sided adhesive tape is only intended to hold the junction box in place during the time required
to cure the silicone adhesive. The tape is not intended to hold the box in place with PV4 cables attached. If cables are
attached to the box before the silicone adhesive is applied, the cables must be supported to prevent stressing the silicone
adhesive while it cures. The customer must develop and qualify a robust solar box mounting procedure to insure the silicone
adhesive fully cures with an airtight seal between the junction box and their specific solar panel materials & surface finish.
DANGER
When working with Silicone sealant, avoid contact with eyes. If eye contact occurs, rinse the eyes for 15 minutes and seek
medical attention. Avoid prolonged contact of Silicone with skin.
3. A 6- to 9-mm wide band of the Silicone sealant must be applied to the attachment area (located on the
bottom) of the base (shown in Figure 4). The band must be continuous and free of gaps. If desired, the
band may be smoothed using a small spatula or brush to ensure a uniform and gap-free application.
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Glass-Glass
RTV
Sealant Channel:
Do Not Apply
sealant directly
into the channel

Edge Guide Features
Figure 4 (cont’d)
Traditional Mid-Panel
RTV
Outline of Box
Final Location
Figure 4 (end)
4. The junction box must be placed onto the attachment area of the solar panel with the foil tabs of the
solar panel routed through the back of the open area of the junction box. For Glass-Glass, use the built-in
edge guides on the box to align the box with the edge of the solar panel.
5. The junction box must be oriented horizontally, then pressed onto the solar panel until it is secure. The
diodes, diode legs, and contact rails must not be handled or pressed when securing the junction box to
the solar panel. To ensure adequate Silicone sealant coverage in the attachment area, a 1-kg [2-lb] metal
weight can be positioned on the top of the closed lid of the junction box.
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CAUTION
Do not allow excess sealant to flow into the lid sealing zone, onto the foil or contact rails, or into the PV4 interface areas. Extra
care is needed around the + Box with the integrated PV4 Connector. Excess sealant can extrude out from under the junction
box into the PV4 mating face zone. After the sealant cures in this zone, it can impede mating the PV4 connector. The + Type
Boxes have a channel to allow excess sealant to flow into the channel away from the PV4 interface area. Do not apply
sealant directly into the channel.
CAUTION
Handling or pressing the diodes, diode legs, or contact rails can cause mechanical stress on the components and result in
malfunction of the solar panel.
6. The junction box must be kept in a horizontal position until the adhesive has fully cured. The Silicone
sealant must be fully cured before terminating or testing the junction box.
7. For Glass-Glass mounted junction boxes, attach the edge flap using the following procedure shown in
Figure 5:
a. Apply a bead of RTV approximately 5 mm (minimum) in diameter along the inside corner of the
edge flap and along its perimeter. Also apply RTV to the small areas of exposed foil that exits
between the glass layers on the edge of the panel. Be sure to completely cover the foil with the
RTV to insure a good seal. The flap has a recessed area in the center top place optional double
sided tape to hold the flap in place until the RTV cures.
b. Insert the edge flap into the track features integrated into the junction box.
c. Rotate the edge flap closed and press the flap against the top side of the panel.
Optional Tape
(customer supplied)
RTV (cover the
exposed foil)
Figure 5
NOTE
The Silicone adhesive must be allowed to fully cure, before the termination process.
3.7. Termination
1. Each foil tab of the solar panel must be positioned on the junction box as follows. See Figure 6.
JUNCTION BOX TYPE
Foil Clamp Ω Clip
Foil Clamp S Clip
FOIL TAB THICKNESS
0-0.45 mm
>0.45 mm
0-0.6 mm
FOIL TAB POSITION
Wrapped Over Interface Tab of Contact Rail ■
Laid Against One Side of Interface Tab of Contact rail
Insert the Foil Tab Into Clamp Gap While Opening the Clamp
REFER TO
Figure 7
■To avoid buckling and improper seating of the foil clip, the foil tab should be wrapped over the interface tab as far as possible past the serrations of the interface tab
without touching the contact rail. Refer to Figure 7.
Figure 6
2. For the Ω clip type junction box, using the foil clip pliers, the open end of each foil clip must be spread
apart to a maximum of 1.5 mm to enable the foil clip to slide over the thickness of the foil tab of the solar
panel and interface tab of its respective contact rail, and then released. One Ω foil clip must be installed
onto each interface tab. Refer to Figure 7.
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Ω Clip
Install Ω Clips Over Tabs
Fold Foil Tabs Over Contact Tabs
S Clip
Insert Screwdriver into Clip
and Pry the Clip Open
Then Route Foil into
Opening in Clip
Figure 7
3.8. Cable Routing and Strain Relief (Figure 8)
The cable connection to the box is designed to be mated in an axial direction. Any mating, un-mating or cable
pull applied in a non-axial direction could result unintended damage to the box and or mating cable connector.
NOTE
Care should be taken to ensure that the cable is not used to carry the solar panel during application.
CAUTION
Cables must not bend, stretched, crushed, or confined in any way. The cables must not be bent in the direct exit of the cable
screw joint. A minimum bend radius of greater than five times the diameter of the largest cable must be maintained. The cable
must be routed so that tensile or angular stress on the connections is prevented. If possible within the application it is
recommended that the cable is attached in the application to help to eliminate any potential angular stress applied to the
connection.
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
Figure 8
DANGER
To avoid personal injury, the circuit load must be DISCONNECTED BEFORE a cable coupler is unplugged. A cable coupler
MUST NOT be unplugged under load.
A hand application tool (P/N 1971903-1) is available for disconnecting the couplers.
1. The locking mechanism is opened by depressing the latches with this tool as shown in Figure 9.
2. Disconnect the coupler connection while the special tool insertion into the locking mechanism to
depress the latches, and pull the couplers apart.
1
1
2
2
Figure 9
3.9. Closing the Lid (Figure 10)
The lid of the junction box must be attached to the base and then closed properly with the following
requirements:
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NOTE
If the lid is equipped with a Thermal Interface Material (TIM) pad, peel off the film from the TIM before installing the lid.
1. The two attachment tabs of the lid must be inserted into the recesses of the base. The attachment
tabs must be properly seated so that the lid can freely rotate when closed.
2. When closed, the latch of the lid must lock into the fastening lugs of the base (there will be an audible
“click”). The bottom surface of the lid must be flush with the top surface of the base. The lid must be flat
(not bulging). The O-ring of the lid must sit in the groove around the perimeter of the base. No part of the
O-ring can protrude from the base.

O-Ring Protruding
Between Base and Lid
Figure 10
CAUTION
To ensure proper sealing of the junction box and avoid damage to the components inside of the junction box, the O-ring of the
lid must be properly fitted in the groove around the base and the lid must be tightly fitted to the base when the lid is closed.
3.10. Opening the Lid
CAUTION
Only authorized and trained personnel should open the lid of the junction box.
DANGER
To avoid personal injury or death, the lid of the junction box must NEVER be opened while the junction box is under electrical
load. Components inside the junction box may be electrically charged and capable of causing severe injury or death.
EXTREME CAUTION must be taken when opening the lid of the junction box.
To open the lid of the junction box, the tip of a screwdriver having a 3 to 5-mm flat blade must be inserted into
the release pocket of the lid, and then the attachment tab must be pried free while simultaneously slightly lifting
the front of lid. See Figure 11.
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Insert Screwdriver
Blade into Latch
Window
Pry Latch Open
Lift Lid Using
Edge Extending
from the Lid
Figure 11
3.11. Serial Wiring Diagram
Figure 12 provides a typical serial wiring diagram.
Figure 12
4. QUALIFICATIONS AGENCY APPROVALS
This product line has been sent for agency review and evaluation to UL3730 and IEC-62790.
NOTE
This product is intended to be installed at ambient conditions of 0°C or above per UL3730 section 28.4 and section 41.9.
Product use temperature range is specified within applicable agency certificates.
5. TOOLING
The foil clip pliers are used to spread the open end of the foil clip for installation. See Figure 13.
Foil Clip Pliers 5-1579002-0
Figure 13
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6. VISUAL AID
The illustration below shows a typical application of this product. This illustration should be used by production
personnel to ensure a correctly applied product. Applications which do not appear correct should be inspected
using the information in the preceding pages of this specification and in the instructional material shipped with
the product or tooling.
LID SEATED (O-RING NOT
EXPOSED ALONG ENTIRE
PERIMETER)
LATCH
RTV SEAL
SECURED
(ALONG ENTIRE
FLAP EDGE)
LATCH
SECURED
FLAP IN
TRACK
DUST CAP IN PLACE
ON “+” END BOX
LID SEATED (O-RING NOT
EXPOSED ALONG ENTIRE
PERIMETER)
RTV SEAL (BETWEEN
STANDOFFS ON BASE)
RTV SEAL (FLAP ON
TOP SIDE OF PANEL)
TOP SURFACE OF FLAP
PARALLEL TO TOP
SURFACE OF PANEL
DUST CAP IN PLACE
ON “-” END BOX
THERE MUST NOT BE
ANY SEALANT IN THE
PV4 INTERFACE
Figure 14 VISUAL AID
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