assembly instructions radox solar connector with twist … · solar connector with twist locking...

HUBER+SUHNER Excellence in Connectivity Solutions

ASSEMBLY INSTRUCTIONS RADOX® solar connector with twist locking

Edition 2007

HUBER+SUHNERPage II

HUBER+SUHNER Page �

Content

1 Type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 EU statement of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

5 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

6 Required components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Connectors for solar cable 4 mm2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Connectors for solar cable 6 mm2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7 Required tools and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

9 Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 9 .1 Connecting and locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 9 .2 Unlocking and disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

10 Maintenance of tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1110 .1 Solar stripping tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1110 .2 Solar crimping tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

11 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

HUBER+SUHNERPage 2

1 Type designationSolar connector with twist locking consisting of:

Solar plug CL+ Solar socket CB–

Type designation is found on the grip hood.

2 EU statement of conformityWe hereby declare, that this product has been developed and produced in accordance with the essential requirements of the directive DIN V VDE V 0�26-3 and the European directive 2006/95/EG.

2006

HUBER+SUHNER AG CH-8330 Pfäffikon ZH

Thomas Grimberg, Product Management Thomas Berchtold, Product Qualification

3 ApplicationThe solar connectors and solar cables are designated for fixed installation in dry or humid rooms or outdoor use for the connection of photovoltaic components. They are not suitable for the connection of portable equipment or for continuous operating in water or in direct burial applications.

Warning: The solar connector is not applicable for connecting and disconnecting under load.

The solar cable is suitable for the following type of installation, reference no. 2, 3A, 4A, 5A, ��, ��A, �2, �3, �4, �5, �6, 2�, 22A, 23A, 24A, 25, 3�A, 32A, 33A, 34A, 4�, 43, 5�, 72, 73, 75 in table 52H of HD 384.5.52 (CH: SEV �000 chapter. 5.2; DE: DIN VDE 0�00-520)

HUBER+SUHNER Page 3

4 Technical data

Application class IEC 6�730-� A

Rated current 38 A

Rated voltage �000 V DC

RMS withstand voltage 6000 V

Rated impuls voltage 8 kV

Degree of pollution EN 60664-� 3

IP protection degree EN 60529 IP 67 in mated condition

Min. operating temperature -40 °C Max. operating temperature +��0 °C Continuous operating temperature +85 °C

Type of connection crimped type connection

Suitable cables RADOX® Solarkabel RADOX® SolarLink RADOX® SMART

Min. bending radius of cable 4 x cable diameter

5 Safety instructions• The parts, tools and accessories from HUBER+SUHNER described in this Assembly

Instructions have to be solely used for assembly and the herein shown procedure has to be strictly followed. If the assembly is not done in accordance with the instructions, neither safety nor performance of technical data can be guaranteed.

• Several operations have to be executed by specialists or skilled employees.

• To avoid electrical shock during assembling, the connectors must be free from voltage.

HUBER+SUHNER

24500094 (Set)

24500095 (Set)

24500092 (Set)

24500083 (Set)

Page 4

6 Required components

6 .1 Connectors for solar cable 4 mm2

6 .2 Connectors for solar cable 6 mm2

Designation Item number Illustration

RADOX® Solarkabel

RADOX® SolarLinkRADOX® SMARTNote: item number is printed on the cable insulation

red �254580� blue �2537896 black �2545802black �2582665black �2583780

Solar plug, consisting of: - plug CL+ 84039626 - grip hood C4 84039627

Solar socket, consisting of: - socket CB– 84039625 - grip hood C4 84039627


RADOX® SolarkabelRADOX® SolarLinkRADOX® SMART

Note: item number is printed on the cable insulation

black �2552756black �2583784black �258378�

Solar plug, consisting of: - plug CL+ 84039626 - grip hood C6 8403964�

Solar socket, consisting of: - socket CB– 84039625 - grip hood C6 8403964�

HUBER+SUHNER

24�0�582

24�0�804

24�0�803

24�0�6�0

24�0�580

Page 5

7 Required tools and accessories


Solar cable cutter

Solar stripping tool

Solar crimping tool 4/6 mm2

Solar lubricant

Note: The solar lubricant (glycerin dilution approx. 85 %, EG-No. 200-289-5) can be refilled in drugstores or pharmacies.

Measuring tape

HUBER+SUHNER

�

2

3

4

56 mm2

4 mm2

2.5 mm2

Page 6

8 Assembly

Designation Illustration

Cut the cable using the cable cutter to the desired length.

Apply lubricant evenly, approx. 6 cm length.

Note: Insert cable in bottle opening and pull out again.

Slide grip hood with the crimp ring ahead onto the cable end.

Note: Close crimping tool and use it with the large die as "slide sup-port".

Cable cross section grip hood 4 mm2 C4 6 mm2 C6 Warning: By using the wrong grip hood, the tightness and electrical protection of the connector can not be guaranteed.

Adjust the cable stop of the strip-ping tool to 9 ± � mm

9 ± � mm

Choose appropriate knife opening according to cable cross-section as marked.

HUBER+SUHNER

6

7

8

9

4 mm2

6 mm2

�0

��

Page 7


Insert cable and align at the cable stop.

Close the stripping tool continu-ously until the handles touch each other, release handles. Thereby the insulation will be cut and stripped off.

Inspect the stripped cable end of the following: - Stripping length 9 ± � mm - No cut off wires - No remaining insulation or residue on the conductor - No lubricant on the conductor

Choose crimping die according to cable cross-section.

Warning: Damaged dies are not suitable to be used. If parts of the die are broken out, the die has to be exchanged. See chapter �0.2.

Insert plug resp. socket with the crimp barrel first into the die and align centric.

Plug Socket

Close crimping tool slowly until plug resp. socket is slightly fixed but not deformed. This helps to insert the conductor more easily.

Plug Socket

HUBER+SUHNER

�2

max. � mm

�3

Page 8


Insert the conductor completely into the crimp barrel of the plug resp. socket. The distance between crimp barrel and insulation shall not ex-ceed � mm.All wires must be inside the crimp barrel. If not, pull the cable out to align sticking out wires and insert the conductor again.

Warning: If wires are outside of the crimp barrel, a proper crimping result can not be guaranteed! Plug

Socket

Close the crimping tool continu-ously over all six ratchet steps resp. until the ratchet mechanism opens automatically.

Note: The crimping procedure can be interrupted by turning the emer-gency unlocking button.

Warning: The results of an inter-rupted crimping procedure shall not be used or reworked! Cut off such results, dispose them and mount a new plug resp. socket.

HUBER+SUHNER

�4

�5

�6

Page 9


Slide grip hood carefully and com-pletely onto the plug resp. socket without wrinkling. There shall be no gap between the two parts.

Note: Close crimping tool and use it with the middle part of the die as "slide support".

Warning: If grip hood is slided on uncompletely, tightness of the con-nection can not be guaranteed.

Plug Socket

Insert plug resp. socket with the crimp ring ahead in the middle part of the die and align centric.

Close the crimping tool continu-ously over all six ratchet steps resp. until the ratchet mechanism opens automatically.

Note: The crimping procedure can be interrupted by turning the emer-gency unlocking button.

Warning: The results of an inter-rupted crimping procedure shall not be used or reworked! Cut off such results, dispose them and mount a new plug resp. socket.

HUBER+SUHNER

�7

�

2

Page �0


Inspect connectors and cable over the total length for visible damage.

Damaged connectors or cable shall be inspected by a specialist or skilled employee and dis-carded or repaired if necessary .

9 Usage

9 .1 Connecting and locking



Touch the plug at the grip hoods and slide it completely into the socket. The gap left should be about 2 mm. gap of about 2 mm

Screw the plug into the socket until the gap is closed completely. (= locked)

Note: The direction to lock the con-nector is labeled on the griphood.

HUBER+SUHNER

�

2

�

2

Page ��

10 Maintenance of tools

10 .1 Solar stripping tool

The stripping tool has to be in proper and clean condition before starting to work. Avoid soiling. Oil the hinges regularly with light machine oil. Make sure, that all bolts are secured with snap rings and screws are tightened.

Exchange of blades

If cable insulation is not cut properly anymore, all four blades have to be exchanged. A service kit with replacement blades and compatible Allen key can be ordered at HUBER+SUHNER, item no. 24�0�8�0.


Remove the Allen screws.Close the tool and remove all four blades.

Attach the new blades onto the re-tention pins (grinded sides inlying).Put the tool back to its original posi-tion.Secure the blades with the Allen screws.

9 .1 Unlocking and disconnecting



Touch the connectors at the grip areas and unscrew until a gap of 2 mm occurs.

Pull plug and socket completely apart. (= disconnecting)

HUBER+SUHNERPage �2

10 .2 Solar crimping tool

The crimping tool has to be in proper and clean condition before starting to work. Avoid soiling. Do not treat the crimping die with agressive or abrasive agents. Oil the hinges regularly with light machine oil. Make sure, that all screws and bolts are secured with snap rings.

Tensile strength of the crimp connection is: for cable cross-section 4 mm2: min. 3�0 N for cable cross-section 6 mm2: min. 360 N.

Warning

Tool and dies wear out in normal use. A proper crimp result can not be guaranteed with a worn out tool! The tool must be inspected and eventually repaired by a specialist after max. 50'000 crimpings.

A service kit with replacement dies and compatible Allen key can be ordered at HUBER+SUHNER, item no. 24�0�809.

11 DisposalSolar connectors and cable (EAK-Code �7 04 ��) can be partially recycled. Check with local guidelines for proper recycling methods.

HUBER+SUHNER Page �3

8402

97�7

(de/

en),

�0.2

007

WAIVER

It is exclusively in written agreements that we provide our customers with warrants and representations as to the technical specifications and/or the fitness for any particular purpose. The facts and figures contained herein are carefully compiled to the best of our knowledge, but they are intended for general informational purposes only.

HUBER+SUHNER is certified according to ISO 9001 and ISO 14001 .

Huber+Suhner AGWire+Cable CH-8330 Pfäffikon ZHTel. +4� (44) 952 22 ��Fax +4� (44) 952 26 70www.hubersuhner.com

assembly instructions radox solar connector with twist … · solar connector with twist locking...

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