Installation Manual

for PV-JK03M/xy Series

Cable Connector

JinkoSolar Switzerland AG JinkoSolar GmbH JinkoSolar Enerji Teknolojilero A.Ş.

Chamerstrasse 85 Freisinger Straße 9 NİDA KULE İş Merkezi Göztepe Merdivenköy
6300 Zug SWITZERLAND 85716 Unterschleißheim GERMANY Mah. Bora Sk. No:1, Kat:7 34732, Kadıköy,
Tel: +41 41 748 0010 Tel: +49 89 1433246-0 Istanbul, TURKEY
Fax: +41 41 748 0019 Fax: +49 89 1433246-29

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. j e t. o r .

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www.jinkosolar.eu | Technical Support: [email protected]
 Table of Contents

1.Products Overview 04

2.Tools and Parts Overview 05

3.Technical Data 06

4.Tools Instruction 07

5.Installation Instruction 08

5.1 Cable Preparation 08

5.2 Crimping 09

5.3 Male/Female Terminals Installation 12

5.4 Disconnecting Cable Connector 13

5.5 Installation Warning 14

02 Installation Manual for PV-JK03M/xy Series Cable Connector | 03

 1.Products Overview 2.Tools and Parts Overview

Item Tool Type Tool Name Pic.

6
2 3 4
5
1 1 JKT-01 Stripping Tool

2 JKT-02 Crimping Tool

Assembly Tool
3 JKT-03 Open-end-Wrench
8
7 3 4
5

4 JKT-04 Universal Tool

1. O Ring 5. Gland Nut 4JB03M31005

5 Dust plug
4JB03M31007

2. Male Housing 6. Female Terminal

3. Lock Termina 7. Female Housing

6 JKT-08 Torque wrench

4. Cable Gland 8. Male Terminal

04 Installation Manual for PV-JK03M/xy Series Cable Connector | 05

 3.Technical Data 4.Tools Instruction
Type Name or Model No. PV-JK03M/xy Series
The Stripping Tool-JKT-03 is applicable to 2.5mm²(14AWG) or 4.0mm²(12AWG) or
1000 V DC/1500 V DC (IEC: PC only for 1000V) 6.0mm²(10AWG) cable.
Rated Voltage ( V DC) 1000 V DC/1500 V DC (UL) There is one stripping tool JKT-04 per tool set.
6000 V (1000 V DC) Function: Cutting the wire insulation (exposing the copper wire).
Rated Insulation Voltage 8000 V (1500 V DC)

30 A (2.5mm²/14AWG)
45 A (4.0mm²/12AWG)
Rated Current (A DC)
50 A (6.0mm²/10AWG)
60 A (10.0mm²/8AWG)

Application Class Class A

Protection Class / Pollution Degree Class II / 2 Stripping Tool - JKT-01

The Crimping Tool-JKT-02 is applicable to 2.5mm²(14AWG) or 4.0mm²(12AWG) or
Ambient Temperature -40 to 85
6.0mm²(10AWG) cable.
There is one crimping tool-JKT-02 per tool set.
Upper Limit Temperature 105 (IEC)
Function: The connection and crimping between the copper wire and metal
terminals are all made by the crimping tool.
Over Voltage Category CAT III

Flammability Class UL94 V-0

IP68(1m, 2h) in mated condition

Degree of Protection, mated / unmated
IP2X in unmated condition

1X2.5mm²(14AWG) for y=A

Wire Cross Section Area or Cross 1X4.0mm²(12AWG) for y=B
Section Range 1X6.0mm²(10AWG) for y=C
Crimping Tool- JKT-02
1X10.0mm²(8AWG) for y=D Assembly Tool -JKT-03 There are two assembly tools per tool set. Universal Tool-
Rewireable No JKT-04 :There is a universal tool per tool set.
Function: To disassemble the cable connector and disconnect male / female
5,00mm to 8,50mm (IEC) cable connector.
Cable Diameter
6,20mm to 9,00mm (UL)

Contact Resistance ≤ 0.3 m Ω

Contact material Copper, tin plated

Insulation Material m-PPE /PC/ PA66

Existence of an enclosure Enclosed connector

Certification Standard IEC62852

UL6703

Note: PV-JK03M-F/xy ; PV-JK03M-M/xy (x=1 or 2, y=A or B or C or D)

06 Installation Manual for PV-JK03M/xy Series Cable Connector | 07

 5.Installation Instruction
5.1 Cable Preparation 5.2 Crimping

According to different specifications of cables, please select the appropriate configura- 5.2.11 Manual Tools Crimping
tion from table 1:
Table-1 When crimping with specified Crimping tools e.g. JKT-02 , insert striped cable into
contact barrel and insure all conductor strands are captured in the contact barrel.
Conductor cross section Connector configuration
Crimp contact barrel by using the corresponding crimping die, See below pictures
mm2 AWG For TÜV & UL from Fig.3 to Fig.7. Check whether the crimping is firm after the crimping is complet-
2.5 14 PV-JK00M1/1y ed. (Fig. 8). The pull-out force has to meet below table-1.

4 12 PV-JK00M1/2y

6
Table-2
10 PV-JK00M1/2y

10 8 PV-JK00M1/3y
No. Cable Size Cable Crimping Pull-Out Force

Do not use untreated cables. Tinned wires are recommended. L=7-9mm

When stripping the cable insulation “L”, 7mm to 9mm in length should be removed on the 1 2.5mm²/14AWG ≥223 NMin.223 N

end of cable.
2 4.0mm²/12AWG ≥310 NMin.310 N
Do not cut the copper wire inside.
L 3 6.0mm²/10AWG ≥360 NMin.360 N

4 10.0mm²/8AWG ≥400 NMin.400 N

Open the crimping tool and press the clip. Insert the male/female terminal into ap-
propriate groove until fully seated. To make the opening of the male/female terminal
Fix the stripping tool, cutting length to 7mm to 9mm (the length of L should be fixed). face up. (Fig. 3 & 4).
Take the cable one hand and take the stripping tool-JKT-03 the other hand.
Squeeze the crimping tool gradually until the male/female terminal touches the
Insert cables until the end touches fixed block.(Fig. 1) lower half of the crimping mold.(Fig.5).
Squeeze the handle of the stripping tool by hand, then cut and remove the cable insula-
tion.(Fig. 2).

Figure 3 Figure 4 Figure 5

Figure 1 Figure 2

08 Installation Manual for PV-JK03M/xy Series Cable Connector | 09

 Crimping Tool Drawing (Fig 10&11)
Insert the stripped wire into the male/female terminal until the cable insulation touch-
es the opening of the male/female terminal. Press the crimping tool completely. (Fig.
6 7).
Be sure the crimping is completed and fixed. (Fig. 8).

Figure 6 Figure 7 Figure 8

5.2.2 Automatic Machine Crimping Figure 10 Up Blade Figure 11 Down Blade

If customer use the automatic crimping machine, we suggest that the contact crimping
spec. should meet the table-2 requirement. 12AWG/4mm2
Note: The above crimping tool drawing are only for 12AWG/4mm2 cable.
It is very important to do a micro-cutting tests, the test should be contained following
items: REF. Fig.9 .
If the compression rate can't meet recommened technical requirement, we suggest that Crimping Tool Drawing (Fig 12&13)
secondary soldering tin process should be adopted at the cable and conductor connec-
tion , to ensure a reliable connection.

(Table-2 Cable cross-sectional Analysis)

Spec.
NO. Cross-Sectional
12AWG/4mm² 10AWG/6mm²

1 CH Crimp Height 2.30±0.05mm 2.60±0.05mm

2 CB Crimp Width 4.00±0.10mm 4.25±0.10mm

3 CBm Measurable Crimp Width 1.0*CB≤CBm≤1.1*CB 1.0*CB≤CBm≤1.1*CB

4 D Crimp face Ends D ≤ 0.35mm D ≤ 0.35mm

5 GH Burr Height GH ≤ 0.7mm GH ≤ 0.7mm

6 GB Burr Width GB ≤ 0.5mm GB ≤ 0.5mm

7 CH/CB Crimp Height/Crimp Width 50%≤(CH/CW)≤70% 50%≤(CH/CW)≤70%

Figure 9 8 C/R Compression Ratio 75%≤C/R≤85% 75%≤C/R≤85% 10AWG/6mm2

9 P Void Ratio ≤1.00% ≤1.00% Note: The above crimping tool drawing are only for 10AWG/6mm2 cable.

Note: The above cross-sectional analysis is only for 12AWG/4mm2 & 10AWG/6mm2 cable.

10 Installation Manual for PV-JK03M/xy Series Cable Connector | 11

 5.3 Male/Female Terminals Installation 5.4 Disconnecting Cable Connector

Insert the crimped male or female terminal into back of male or female cable connector Insert the forks into the buckle of the cable connector by the universal tool.
(Fig.14). A “click” should be heard or felt when the contact cable assembly is seated in (Fig. 20)
correct position. Contacts cannot be removed once seated. (Fig.15) Pull the cable connector by hand respectively. The cable connector can
now be separated.(Fig. 21 to 22)

Figure 14 Figure 15 Figure 16

To fixed the gland nut by the torque wrench-18mm of the assembly tool, and to fixed the Figure 20 Figure 21
male cable connector or female cable connector by the another assembly tool, then
tighten the gland nut with the specified tightening torque.(Fig. 16).

Tighten the gland nut clockwise by using a tool or a torque wrench, refer to the torque
values in the table below and ensure that the nut is screwed to the anti-loosing position
and can be buckled. Take onsideration of the production process of different wire manu-
facturers and the softness and hardness of insulation/sheath material.To avoid damage to
the nut and prevent deformation,do not screw the nut to the bottom of the body (It is rec-
ommended to leave a gap of 0.8~1.5mm) (see Figure 17).
Figure 22
Insert the female cable connector into the male cable connector when the gland nut is
fully tightened. The connection of female and male cable connector is complete when
an “audible click” is heard. (Fig. 18 & 19).

Cable Size Tightening Torque

4mm²/12AWG 2.0~2.5 N.m

6mm²/10AWG 2.0~2.5 N.m

Figure 17

Figure 18 Figure 19

12 Installation Manual for PV-JK03M/xy Series Cable Connector | 13

 5.5 Installation Warning

If parts and tools used are not specified by JinKO or not prepared and assembled as
JinKO described during installation , the uniformity of safety and technical data on prod-
ucts are not guaranteed.

The connector is considered to be in compliance with UL 6703 only when assembled in

the manner specified by these assembly instructions.

During assembling, the connector must not be touched with any machine oil, grease, sol-
vent, with which connector would be out of action. Notice that the gloves the operators
used must not contain the substance above. The male cable connectors and the female
connectors must not plugged together when soiled.

The work described here must not be carried out on live or load-carrying part.
Connectors must not be disconnected under load. Plugging and unplugging when volt-
age is permitted.

The dust plug 4JB03M31005/4JB03M31007 should be placed to avoid exposing the dust
and water when disconneted or disconnected after connected.

The plug connectors are watertight in accordance with IP68 protection class. However,
they are not suitable for continuous operation under water. Do not place the connectors
directly on the roof.

The plug connection must not be subjected to continuous mechanical tension. The cable
should be fixed with cable binders.

For safety reason, the use of either PVC cables or untinned cables are prohibited.

This connector is suitable for use only with Class B and C stranded copper conductors (See
NFPA NEC 70 Chapter 9, Table 10).

Notes: If you have any questions during installation, please feel free to contact us as follows:

Jiangxi Jinko PV Material Co., Ltd.

AddNo.10, Xingye Road, Economic Development Zone, Shangrao ,Jiangxi Province, P.R. China

Tel.+860793-8876086
Postcode334100
Websitewww.jinkopvm.com

Sales Contact Information

Tel.+860793-8876028
[email protected]

Technician Contact Information

Tel.+860793-8876018
[email protected]

14 Installation Manual for PV-JK03M/xy Series Cable Connector | 15