Trina Solar TS4-F1 User manual

天合光能 TS4 连接器安装手册
Trina Solar TS4 Connector Installation Manual
1
文件编号 File No：PS-M-0779
版本 Version：F
日期 Date：2021.10.12

天合光能 TS4 连接器安装手册
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目录
Table of Content
1.安全说明 Safety Instruction ................................................................................................. 4
1.1 警告 Warning ................................................................................................................. 4
1.2 通用安全 General Safety ............................................................................................... 4
1.3 操作安全 Handling Safety.............................................................................................. 5
2.技术参数 Product Specifications .......................................................................................... 7
3.产品选型表 Product Selection Form .................................................................................... 8
3.1 TS4 连接器 TS4 PV connector....................................................................................... 8
3.2 TS4 Plus 连接器 TS4 Plus PV connector......................................................................... 8
4.连接器外观尺寸图 Connector Appearance Size Drawing ................................................... 9
4.1 TS4 连接器 TS4 PV connector........................................................................................... 9
4.1.1 正极连接器 Positive Connector.............................................................................. 9
4.1.2 负极连接器 Negative Connector.......................................................................... 10
4.2 TS4 Plus 连接器 TS4 Plus PV connector......................................................................... 11
4.2.1 正极连接器 Positive Connector........................................................................... 11
4.2.2 负极连接器 Negative Connector.......................................................................... 11
5.安装 Installation.................................................................................................................. 11
5.1 工具要求 Tools Requirements..................................................................................... 11
5.1.1 剥线钳 Wire Stripper ............................................................................................ 11
5.1.2 铆接钳 Rivet Plier.................................................................................................. 12
5.1.3 塑料板手 Plastic Unlocking Spanner .................................................................... 13
5.1.4 工具箱 Tool Box .................................................................................................... 13
5.2 组装步骤 Assembly Steps............................................................................................ 14
5.2.1 剥线 Stripping ....................................................................................................... 14
5.2.2 放入插针插套 Inserting pin and socket ............................................................... 14
5.2.3 铆接插针插套 Crimping pin and socket ............................................................... 15

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5.2.4 插入 Pushing ......................................................................................................... 17
5.2.5 安装螺帽 Install the nut........................................................................................ 17
6.连接器对插及解锁 Connecting and Disconnecting ........................................................... 19
6.1 连接器对插 Connecting............................................................................................... 19
6.2 连接器解锁 Disconnecting .......................................................................................... 19
7.线缆 Cable........................................................................................................................... 19
7.1 线缆接线 Connection of Cable .................................................................................... 19
7.2 接合状态 Connection Status........................................................................................ 20
8. 天合光能服务网点 Trina Solar Service Point................................................................... 20

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1. 安全说明 Safety Instruction
该产品只能由有相应资质的或经过专家培训的专业人员安装，安装过程中需要遵守所有
安全规范。天合光能不承担对于因不遵守这些警告而产生的任何责任。
The products may be installed only by suitably qualified and trained specialists with due
observance of all applicable safety regulations. Trina Solar declines any liability in the event of
failure to observe these warnings.
1.1 警告 Warning
1.1.1 仅可使用天合光能指定的零件和工具。对于自行装配，请务必遵守本文所述的
准备和安装的说明，否则天合光能不予保证对于产品的安全性及技术参数的一
致性。对于产品请勿做任何形式的修改。
Use only the components and tools specified by Trina Solar. Do not deviate from
the preparation and assembly procedures described here, since in this event, in the
situation of self-assembly, no guarantee can be given as to safety or conformity
with the technical data. Do not modify the product in any way.
1.1.2 必须与天合光能认可的连接器相连接，否则天合光能不承担任何责任。
Connector must be mated with connector qualified by Trina Solar, otherwise Trina
Solar will disclaim any warranty responsibility.
1.1.3 不能在有负载的情况下插拔连接器。在带电情况下允许插拔，但一定要切断光
伏系统端电源。Do Not Disconnect under Load. Plugging and unplugging when
live is permitted, but the power at the PV system must be cut off.
1.2 通用安全 General Safety
1.2.1 确认终端产品有防电击功能并确认其使用者采取了防电击措施。
Protection from electric shock must be assured by the end product and its user.
1.2.2 为防止电击，在安装和拆卸连接器时必须断开电源。
To prevent electric shock, system must be disconnected from the power source
when the connector is installed or disassembled.
1.2.3 连接器不能承受持续的机械拉伸，线缆应该由线缆扎带固定。
The plug connection must not be subjected to continuous mechanical tension. The
cable should be fixed with cable ties, avoiding any pull on the connectors.

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1.2.4 不要将连接器直接放在屋顶表面。
Do not place the plug connectors directly on the roof membrane.
1.3 操作安全 Handling Safety
1.3.1 该连接器仅适用于B类和C类多股铜导线（见NFPA NEC 70第9章，表10）。建
议使用光伏专用线缆，镀锡铜芯，双层绝缘，绝缘材料为XLPE。不建议使用
无镀锡线缆或PVC线缆，否则天合光能不承担任何责任。
The connector is only applicable to the B and C types of copper wires (see
chapter-9 of NFPA NEC 70, table 10). It is recommended to use special
photovoltaic cable, tin plated copper core, double insulation, and XLPE insulating
material. Trina prohibits the use of untinned cable PVC cables, otherwise Trina
Solar will disclaim any warranty responsibility.
1.3.2 未插合状态的连接器必须使用防尘塞，以防止灰尘和水进入。被污染的公母插
头不能插合。
Unmated plug connectors must protected from moisture and dirt with a sealing cap.
If soiled, the male and female connectors must not be plugged together.
1.3.3 插合部件防水等级IP68。不能长久置于水下使用。
The plug connectors are watertight in accordance with IP68 protection class.
However, they cannot be used for continuous operation underwater.
1.3.4 连接器不得在含有烃、酚、酮、氨合物等与塑料有腐蚀的环境中使用。连接器
零件不能暴露于因直接降雨、冷凝等带来的水汽中。确保各零件不能与酸、碱、
瓦斯、丙酮或任何其他会影响材料使用的化学物质接触。安装过程中，禁止在
连接器里添加或涂抹任何油脂及润滑剂。
Do not use under hydrocarbon, phenol, Ammine and plastic corrosive environment.
The components must not be exposed to moisture due to direct rainfall,
condensation, etc. Ensure that the individual components do not come into contact
with acids, alkalis, gases, acetone, or other chemical substances that could
negatively impact the materials used. During installation process, do not add any
grease and lubricant in the connector.
1.3.5 对产品有影响的常见化学品清单如下，对于表中未列明的化学品，需经天合确

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认无影响后再使用。
Below is the list of common chemicals that can affect the products. For other
chemicals not listed in the table, please confirm with Trina Solar Technical Service
BEFORE use (see Section#8).
序号 NO.
化学品名 Chemical Name
1
润滑油 Lubricating oil
2
防锈油 Rust-proof oil
3
冲压油 Stamping oil
4
黄油 Grease
5
机油 Engine oil
6
柴油 Diesel
7
食用油 Cooking oil
8
WD40
9
香蕉水 Banana oil
10
油性封孔 Oil sealing agent
11
乙酸乙酯 Ethyl acetate
1.3.6 储存运输，建议温度为-30℃~ +60℃，相对湿度低于70%，避光、防水、防尘。
不可与有影响的化学品存放在一起。未连接的连接器建议在一年内安装使用。
We recommend TS4 connector storage and transportation temperature between be
-30℃ and +60℃ and a relative humidity of less than 70%. Storage and
transportation at normal temperature must avoid direct sunlight, moisture, and dust.
It is not allowed to be stored with the affected chemicals. The plug connectors
should be installed within one year of delivery by Trina Solar.
1.3.7 天合光能有权随时对本说明书中可能出现的打印错误，产品技术改进和创新等
方面作修改，这些改动恕不另行通知。同时各语言版本翻译的不详之处，请以
中文版为准。最终解释权归天合光能.
Trina Solar has the rights to make certain correction for the printing errors,
improvements and innovation for the products, and there will be no prior notice
when these changes happen. If there was any misunderstanding for the version in

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different language, please regard Chinese version as the right one. Final
explanation right belongs to Trina Solar.
2. 技术参数 Product Specifications
连接器系统 Connector system
Φ4mm
额定电压 Rated voltage
IEC 1500V&UL 1500V
额定电流 Rated current @IEC（85℃）
41A（4.0mm2/ 12AWG）
46A（6.0mm2/ 10AWG）
55A（10.0mm2/ 8AWG）
额定脉冲电压 Rated impulse voltage
16KV
环境温度范围 Ambient temperature range
-40℃~+85℃
接触电阻 Contact resistance
≤0.5mΩ
应用等级 Application degree
Class A
防护类别 Protection class
Class Ⅱ
污染等级 Pollution degree
2
防护等级 Degree of Protection
IP68（1m，1h），已插合 mated
IP2X，未插合 unmated
阻燃等级 Flame class
UL94-V0
绝缘材料 Insulation material
m-PPE/PA
金属材料 Contact material
铜，镀锡 Copper , Tin-plated
接线方式 Type of termination
铆接 Crimping
锁紧系统 Locking system(UL)
嵌入式 Locking type
TUV ,IEC62852
R50401767/R50385924/ R50508240
UL,UL6703
E486009

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3. 产品选型表 Product Selection Form
3.1 TS4 连接器 TS4 PV connector
型号 Type
料号 P/N
线缆
外径
Cable
OD
导体截面积
Conductor
Cross Section
工具料号 Tool P/N
剥线钳料
号Wire
Stripper
P/N
压接工具
料号
Rivet Plier
P/N
扳手料号
Spanner
P/N
mm
mm2
AWG
TS4-F1
7A000986
4.7-6.0
4.0/6.0
12/10
7A001039
7A001038
7A001040
TS4-M1
7A000987
TS4-F2
7A000982
5.6-6.8
TS4-M2
7A000983
TS4-F3
7A002404
6.0-6.6
TS4-M3
7A002425
TS4-F4
7A000984
6.0-7.2
TS4-M4
7A000985
TS4-F5*
7A000992
7.2-8.7
7A001036
TS4-M5*
7A000981
TS4-F6*
7A000990
10.0
8
7A001037
TS4-M6*
7A000991
TS4-F7*
7A004375
6.6-7.2
4.0/6.0
12/10
7A001039
7A001036
TS4-M7*
7A004378
TS4-F8*
7A004377
5.6-6.6
TS4-M8*
7A004376
TS4-F9
7A002997
6.9-7.5
4.0/6.0
12/10
7A001038
TS4-M9
7A002996
3.2 TS4 Plus 连接器 TS4 Plus PV connector
型号 Type
料号 P/N
线缆
外径
Cable
OD
导体截面积
Conductor
Cross Section
工具料号 Tool P/N
剥线钳
料号
Wire
Stripper
P/N
压接工具料
号
Rivet Plier
P/N
扳手料号
Spanner
P/N
mm
mm2
AWG
TS4 Plus-F1
7A004669
4.7-6.0
4.0/6.
0
12/10
7A0010
39
7A001038
7A00454
1
TS4 Plus-M1
7A004670
TS4 Plus-F2
7A004671
5.6-6.8

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TS4 Plus-M2
7A004672
TS4 Plus-F3
7A004673
6.0-7.2
TS4 Plus-M3
7A004674
注意 1：选择与线缆匹配的连接器规料号，需保证导体截面积和线缆外径均在范围内。
否则会影响使用，并产生安全风险。
Note 1：Select the connector specification and Part No. matched with the cable, and ensure
that the cross-sectional area of the conductor and the OD of the cable are within the range.
Otherwise, it will affect the use and create safety risks.
注意 2：带 * 的规格为 O型金属端子的连接器。
Note 2：The specification of connector with * is O-type metal terminal.
4. 连接器外观尺寸图 Connector Appearance Size Drawing
4.1 TS4 连接器 TS4 PV connector
4.1.1 正极连接器 Positive Connector
TS4-F1、TS4-F2、TS4-F3、TS4-F4、TS4-F9：
TS4-F5、TS4-F6、TS4-F7、TS4-F8：

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4.1.2 负极连接器 Negative Connector
TS4-M1、TS4-M2、TS4-M3 、TS4-M4、TS4-M9：
TS4-M5、TS4-M6、TS4-M7、TS4-M8：

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4.2 TS4 Plus 连接器 TS4 Plus PV connector
4.2.1 正极连接器 Positive Connector
TS4 Plus-F1、TS4 Plus-F2、TS4 Plus-F3
4.2.2 负极连接器 Negative Connector
TS4 Plus-M1、TS4 Plus-M2、TS4 Plus-M3
5.安装 Installation
5.1 工具要求 Tools Requirements
5.1.1 剥线钳 Wire Stripper
7A001039 7A001037

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7A001039 7A001037
料号
P/N
钳口
Jaw
剥线范围
Crimping Range
7A001039
中间 Middle
4.0mm2
12AWG
右边 Right side
6.0mm2
10AWG
7A001037
右边 Right side
10.0mm2
8AWG
5.1.2 铆接钳 Rivet Plier
7A001038 7A001036
料号
P/N
钳口
Jaw
铆接范围
Riveting Range
图片
Picture
7A001038
中间
Middle
4.0mm2
12AWG
右边
Right side
6.0mm2
10AWG

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7A001036
可调
Adju
stable
4
4.0mm2
12AWG
6
6.0mm2
10AWG
8
10.0mm2
8AWG
5.1.3 塑料板手 Plastic Unlocking Spanner
1套set =2 片pc，TS4 扳手料号 P/N：7A001040，TS4 Plus 扳手料号 P/N：7A004541
5.1.4 工具箱 Tool Box
对于 TS4 连接器 For TS4 Connector：
料号 P/N
剥线钳
Wire Stripper
铆接钳
Rivet Plier
TS4 塑料扳手
Unlocking
Spanner
图片 Picture
7A001039
数量 Qty.
7A001037
数量 Qty.
7A001038
数量 Qty.
7A001036
数量 Qty.
7A001040 数
量Qty.
7A001035
1pc
None
1pc
None
2pcs
7A001034
None
1pc
None
1pc
7A004329
1pc
None
None
1pc
对于 TS4 Plus 连接器 For TS4 Plus Connector：
料号 P/N
剥线钳
Wire Stripper
铆接钳
Rivet Plier
TS4 Plus 塑料
扳手
Unlocking
图片 Picture

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Spanner
7A001039
数量 Qty.
7A001037
数量 Qty.
7A001038
数量 Qty.
7A001036
数量 Qty.
7A004541 数
量Qty.
7A004675
1pc
None
1pc
None
2pcs
5.2 组装步骤 Assembly Steps
组装连接器时，环境温度建议为-15~+35℃。For assembling of components we recommend
an ambient temperature between -15~+35℃.
5.2.1 剥线 Stripping
剥离线缆塑料绝缘层。L=6±0.5mm。Strip the plastic insulating layer of cable. L=6±0.5mm.
注意：不要切断和损坏线缆绝缘塑料下的铜丝线芯。Note: Please pay attention and do
NOT cut off and damage the copper wire core under the cable insulating plastic.
5.2.2 放入插针插套 Inserting pin and socket
7A001038 7A001036
将金属端子（插针或插套）放在铆接工具孔内，铆接孔朝外，使金属端子的最外侧边缘

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与铆接口齐平。钳口选择参照 5.1.2 章节。
Place the metal terminal (pin or socket) in the hole of the riveting tool. The riveting hole is
facing out. The most outer edge of the metal terminal is flat with the riveting interface. Refer to
chapter 5.1.2 for jaw selection.
5.2.3 铆接插针插套 Crimping pin and socket
将剥好线的线芯插入金属端子铆接孔内，需确保所有芯线都在孔内。保证金属件和线缆
线的同轴度。最后按下铆接工具手柄，一直按到底，完成铆接。铜丝都要被包扎。
Insert stripped cable into the rivet hole of the metal terminal, and make sure all the individual
strands are in the hole. Ensure the coaxially of metal parts and cables. Finally, press the riveting
tool handle all the way and press it to the end to complete the riveting. All individual strands
should be crimped.
对于 O型金属端子使用的铆接钳（7A001036），需根据不同规格线缆，先调节钳
口到相应的档位，调节旋钮高度使得金属端子的最外侧边缘与铆接口齐平。如下图。
For the crimping pliers (7A001036) used for O-type metal terminals, adjust the jaw to
the corresponding gear according to different specifications of cables, and adjust the height
of the knob so that the outermost edge of the metal terminal is flush with the riveting
interface. See Below.
旋钮 knob

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档位
Gear
线缆规格
Cable spec
连接器规格
Connector type
4
4.0mm2/12AWG
TS4-F5/F7/F8
TS4-M5/M7/M8
6
6.0mm2/10AWG
8
10.0mm2/8AWG
TS4-F6
TS4-M6
铆接质量应满足 IEC62852 及以下要求。
Qualified crimping samples must meet IEC 62852 and the following criteria.
下方图例为铆接好的插针插套。The picture below are riveted pins and sockets.
金属端子
Metal terminal

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5.2.4 插入 Pushing
将铆接好的金属端子插入正极或负极的塑料本体中，直至其啮合。轻轻拉动线缆，检查
金属件是否啮合牢固。确认负极 pin 针和负极本体同轴。
Insert the riveted metal terminal into the plastic body of the positive or negative until it
engages. Gently pull the cable to check whether the metal terminals are firmly engaged. Confirm
that the negative pin is coaxial with the negative body.
注意：在线缆及金属端子插入塑料本体前，请勿拧开螺帽，防止内部的密封件掉落或者
方向装反。
Note: Before inserting the cable and metal terminal into the plastic body, do NOT unscrew
the nut to prevent the internal seal from falling or installing in the opposite direction.
5.2.5 安装螺帽 Install the nut
先用手预拧紧，再用塑料扳手旋紧线缆螺帽。First screw the nut by hands, then lock tightly

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by plastic spanner.
对于 TS4 连接器 For TS4 Connector：
型号
Type
线缆外径范围
Cable OD range
管控间隙
Control gap
参考扭力
Reference torque
TS4-F1/M1
4.7-6.0mm
0＜X＜1.0mm
3±0.5 N*m
TS4-F2/M2
5.6-6.8mm
TS4-F3/M3
6.0-6.6mm
TS4-F4/M4
6.0-7.2mm
TS4-F5/M5
7.2-8.7mm
1.0＜X≤1.8mm
＜5 N*m
TS4-F6/M6
TS4-F7/M7
6.6-7.2mm
0＜X≤1.0mm
3±0.5 N*m
TS4-F8/M8
5.6-6.6mm
0＜X＜1.0mm
TS4-F9/M9
6.9-7.5mm
0＜X≤1.0mm
对于 TS4 Plus 连接器 For TS4 Plus Connector：
型号
Type
线缆外径范围
Cable OD range
管控间隙
Control gap
参考扭力
Reference torque
TS4 Plus-F1/M1
4.7-6.0mm
0＜X＜1.0mm
3±0.5 N*m
TS4 Plus-F2/M2
5.6-6.8mm
TS4 Plus-F3/M4
6.0-7.2mm
管控间隙示意参照下图。
Refer to the following figure for the Control gap.
注意 1：锁紧螺帽时，需保证线缆线与螺帽同心。
Note 1：Ensure the concentricity of cable and cable nut when you screw cable nut.
注意 2：须确认负极 pin 针和负极本体同轴，再锁紧螺帽。
Note 2：Make sure the negative pin and the negative body are coaxial and then lock the nut.
在此处键入文本

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注意 3：螺帽锁紧时需严格控制间隙 X值。当线缆的外径偏向下限时，管控间隙应偏向
控制值下限；反之，则偏向控制值上限。
Note 3：When the nut is locked, the clearance X value shall be strictly controlled. When the
OD of the cable deviates to the lower limit, the control gap shall deviate to the lower limit of the
control value; On the contrary, it is biased to the upper limit of the control value.
6. 连接器对插及解锁 Connecting and Disconnecting
6.1 连接器对插 Connecting
将连接器正负极对插，直到啮合。轻轻拉动，以检查是否啮合牢固。。
Plug the coupling together until they engage. And pull lightly to check correct engagement.
6.2 连接器解锁 Disconnecting
连接器正负极对插连接后，只能使用TS4塑料板手(7A001040)或TS4 Plus塑料板手
(7A004541)解锁。
The negative and positive terminals of the connectors must be unlocked with the TS4
plastic spanner (part# 7A001040) or TS4 Plus plastic spanner (part# 7A004541).
7. 线缆 Cable
7.1 线缆接线 Connection of Cable

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线缆根部建议保留至少 20mm 未折弯长度，以免因线缆折弯产生的外力引起连接器密封
件变形。
In order to avoid deformation of the cable sealing element from that a force generated by the
bending the wires, the cable should have at least 20mm straight length nearest to the connector.
See figures below.
注意：请参考线缆生产商的最小弯曲半径的详细要求。
Note: Please refer to the detailed instructions on the minimum bend radius specified by the
cable manufacturer.
7.2 接合状态 Connection Status
8. 天合光能服务网点 Trina Solar Service Point
天合光能股份有限公司 Trina Solar Co.,Ltd
地址：中国江苏省常州市新北区天合路2号
ADD: No. 2 Tian He Road, Electronics Park, New District, Changzhou, Jiangsu 213031, P. R.
China
邮编/PO No：213031
网址 Website：www.trinasolar.com
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