Jinko Solar PV-JK03M2 Series User manual

JinkoSolar Switzerland AG
Chamerstrasse 85
6300 Zug SWITZERLAND
Tel: [phone]
Fax: [phone]
JinkoSolar GmbH
Freisinger Straße 9
85716 Unterschleißheim GERMANY
Fax: [phone]
JinkoSolar Enerji Teknolojilero A.Ş.
NİDA KULE İş Merkezi Göztepe Merdivenköy
Mah. Bora Sk. No:1, Kat:7 34732, Kadıköy,
Istanbul, TURKEY
www.jinkosolar.eu | Technical Support: [email protected]
Installation Manual for
PV-JK03M2/xy Series
Cable Connector

Table of Content
Installation Manual for PV-JK03M2/xy Series Cable Connector | 03
1.Products Overview
2.Tools and Parts Overview
3.Technical Data
4.Tools Instruction
5.Installation Instruction
5.1 Cable Preparation
5.2 Crimping
5.3 Male/Female Terminals Installation
5.4 Disconnecting Cable Connector
5.5 Installation Warning
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05
06
07
08
08
09
12
13
14
02

1.Products Overview 2.Tools and Parts Overview
1. O Ring
2. Male Housing
3. Cable Gland
4. Gland Nut
5. Female Terminal
6. Female Housing
7. Male Terminal
Item Tool Type Tool Name Pic.
Stripping Tool1
2
3
4
5
Crimping Tool
Assembly Tool
Open-end-Wrench
Universal Tool
Dust plug
JKT-01
JKT-02
JKT-06
JKT-04
4JB03M31005
4JB03M31007
6Torque wrenchJKT-08
Installation Manual for PV-JK03M2/xy Series Cable Connector | 0504

3.Technical Data 4.Tools Instruction
JKT-01：2.5mm²(14AWG)、4.0mm²(12AWG)、6.0mm²(10AWG)
The Stripping Tool-JKT-01 is applicable to 2.5mm²(14AWG) or 4.0mm²(12AWG) or
6.0mm²(10AWG) cable.
There is one stripping tool JKT-01 per tool set.
Function: Cutting the wire insulation (exposing the copper wire).
JKT-02：2.5mm²(14AWG)、4.0mm²(12AWG)、6mm²(10AWG)
The Crimping Tool-JKT-02 is applicable to 2.5mm²(14AWG) or 4.0mm²(12AWG) or 6.0mm²
(10AWG) cable.
There is one crimping tool-JKT-02 per tool set.
Function: The connection and crimping between the copper wire and metal terminals are
all made by the crimping tool.
Type Name or Model No.
Rated Voltage ( V DC)
PV-JK03M2-F/xy, PV-JK03M2-M/xy
1500 V DC
Rated Insulation Voltage
Rated Current (A DC)
Application Class Class A
Protection Class / Pollution Degree Class II / 2
Ambient Temperature -40℃to ＋85℃
Upper Limit Temperature 115℃
Over Voltage Category CAT III
Flammability Class
Degree of Protection, mated / unmated
UL94 V-0
Rewireable No
Cable Diameter 4.7mm to 8.0mm
Contact Resistance ≤ 0.2 m Ω
Contact material Copper, tin plated
Insulation Material PA
Existence of an enclosure Enclosed connector
Certification Standard IEC 62852 Edition 1.0 2014-11;
UL6703
IP65/ IP68 (1m, 2h) in mated condition
IP2X in unmated condition
8000 V (1500 V DC)
30 A (2.5mm²/14AWG)
45 A (4.0mm²/12AWG)
50 A (6.0mm²/10AWG)
60 A (10.0mm²/8AWG)
Wire Cross Section Area or Cross
Section Range
1X2.5mm²(14AWG) for x=1；
1X4.0-6.0mm² (12AWG/10AWG) for x =2；
1X10.0mm²(8AWG) for x=3；
Note: PV-JK03M2-F/xy ; PV-JK03M2-M/xy (x=1 or 2, y=B or C)
Stripping Tool - JKT-01
Crimping Tool- JKT-02
Assembly Tool -JKT-06
JKT-06:
Assembly Tool -JKT-06：There are two assembly tools per tool set.
Function: Used for assembling and disassembling connectors.
Installation Manual for PV-JK03M2/xy Series Cable Connector | 0706

5.1 Cable Preparation
TÜV, TÜV/UL
Connector configuration in combination with TÜV, TÜV/UL
TÜV、TÜV/UL：
Choose the suitable configuration in Tab. 1 by using TÜV, TÜV/UL (dual) certified cables:
5.2 Crimping
5.2.1 Manual Tools Crimping
JKT-02
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. Crimp contact
barrel by using the corresponding crimping die, See below pictures from Fig.3 to Fig.7.
Check whether the crimping is firm after the crimping is completed. (Fig. 8). The pull-out
force has to meet below table-2.
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
end of cable.
Do not cut the copper wire inside.
7-9mm “L”
Fix the stripping tool, cutting length to 7mm to 9mm (the length of L should be fixed).
Take the cable one hand and take the stripping tool-JKT-01 the other hand.
Insert cables until the end touches fixed block. (Fig. 1)
Squeeze the handle of the stripping tool by hand, then cut and remove the cable insulation.
(Fig. 2).
Figure 1
Figure 3 Figure 4 Figure 5
Figure 2
5.Installation Instruction
Conductor cross section
Ø-range of the cable (mm) Chose Cable Gland Connector configuration
mm2AWG
2.5
4
6
10
14
12
10
8
4.7~6.4
4.7~6.4
6.4~8.0
6.4~8.0
Black
Black
Red
Red
PV-JK03M2/xB
PV-JK03M2/xB
PV-JK03M2/xC
PV-JK03M2/xC No. Cable Size Cable Crimping Pull-Out Force
1
2
3
4
2.5mm²/14AWG
4.0mm²/12AWG
6.0mm²/10AWG
10.0mm²/8AWG
≥223 N （Min.223 N）
≥310 N （Min.310 N）
≥360 N （Min.360 N）
≥400 N （Min.400 N）
Table-1
Table-2
Open the crimping tool and press the clip. Insert the male/female terminal into appropri-
ate groove until fully seated. To make the opening of the male/female terminal face up.
(Fig. 3 & 4).
Squeeze the crimping tool gradually until the male/female terminal touches the lower half
of the crimping mold. (Fig.5).
Installation Manual for PV-JK03M2/xy Series Cable Connector | 0908

5.2.1 Automatic Machine Crimping
If customer use the automatic crimping machine, we suggest that the contact crimping
spec. should meet the table-3 requirements.
It is very important to do a micro-cutting tests, the test should be contained following
items:（REF. Fig.9）.
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
Figure 9
Figure 10 （Up Blade）Figure 11 （Down Blade）
(Table-3 Cable cross-sectional Analysis)
Cross-SectionalNO. Spec.
1
2
3
4
5
6
7
8
9
CH
CB
CBm
D
GH
GB
CH/CB
C/R
P
Crimp Height
Crimp Width
Measurable Crimp Width
Crimp face Ends
Burr Height
Burr Width
Crimp Height/Crimp Width
Compression Ratio
Void Ratio
12AWG/4mm²
2.30±0.05mm
4.00±0.10mm
1.0*CB≤CBm≤1.1*CB
D ≤ 0.35mm
GH ≤ 0.7mm
GB ≤ 0.5mm
50%≤(CH/CW)≤70%
75%≤C/R≤85%
≤1.00%
10AWG/6mm²
2.60±0.05mm
4.25±0.10mm
1.0*CB≤CBm≤1.1*CB
D ≤ 0.35mm
GH ≤ 0.7mm
GB ≤ 0.5mm
50%≤(CH/CW)≤70%
75%≤C/R≤85%
≤1.00%
Note: The above cross-sectional analysis is only for 12AWG/4mm2 & 10AWG/6mm2cable.
Crimping Tool Drawing (Fig 10&11)
Crimping Tool Drawing (Fig 12&13)
12AWG/4mm2
Note: The above crimping tool drawing are only for 12AWG/4mm2cable.
10AWG/6mm2
Note: The above crimping tool drawing are only for 10AWG/6mm2cable.
Installation Manual for PV-JK03M2/xy Series Cable Connector | 1110

5.3 Male/Female Terminals Installation
5.4 Disconnecting Cable Connector
Insert the crimped male or female terminal into corresponding male or female cable con-
nector (Fig. 14). Installation is complete when heard an audible click sound. (Fig. 15).
Insert the female cable connector into the male cable connector when the
gland nut is fully tightened. The connection of female and male cable connec-
tor is complete when an audible click is heard. (Fig. 18 – 19).
To fixed the gland nut by the torque wrench-17mm of the assembly tool, and to fixed the
male cable connector or female cable connector by the another assembly tool, then
tighten the gland nut with the specified tightening torque. (Fig. 16).
Spin clockwise to tighten the gland nut. The acting tightening torque must be adapted to
the solar cables used in each specific case. (Table-4).
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 consideration of the production process of different wire man-
ufacturers 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
recommended to leave a gap of 0.8~1.5mm) ( Fig.17).
Insert the forks into the buckle of the cable connector by the universal tool. (Fig. 20)
Pull the cable connector by hand respectively. The cable connector can now be
separated. (Fig. 21 to 22)
Figure 14 Figure 15
Figure 20 Figure 21
Figure 18 Figure 19
Figure 22
Figure 16
Figure 17
Cross-Sectional
mm2AWG
Cross-Sectional
2.5
4
6
10
14
12
10
8
Nm
3.0
3.5
4.0
4.0
Table-4
Installation Manual for PV-JK03M2/xy Series Cable Connector | 1312

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 products 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 disconnected 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 proof membrane.
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).
Installation Manual for PV-JK03M2/xy Series Cable Connector | 1514