ZERUN Z8X Series User manual

INSTRUCTION MANUAL
Z8X-UM01 Rev.A
1
ZERUN Z8X Series
Junction Box for Photovoltaic Module
Connection System for Solar Panel

Z8X-UM01 Rev.A
INSTRUCTION MANUAL
Zerun Co., LTD
( No.16 Yaxi Road, Zhixi Town, Jintan District, Changzhou City, 213251 Jiangsu , China )
)
2
Content
目录
1. Scope.............................................................................................................................................................1
2. Product Characteristics...............................................................................................................................1
2.1 ProductSpecifications........................................................................................................................... 1
2.2 Features...............................................................................................................................................2
2.3 Product Family...................................................................................................................................... 3
2.4 Related Documents...............................................................................................................................3
3. User Instruction............................................................................................................................................ 4
3.1
Cleaning...............................................................................................................................................4
3.2 Installation Guidelines for the Junction Box Attachment to the PV Modules....................................... 4
3.2.1 Content.....................................................................................................................................4
3.2.2 Equipment............................................................................................................................... 4
3.2.3 Safety Instructions..................................................................................................................5
3.2.4 Assembly Process..................................................................................................................5
3.2.4.1 Preparation Attach Junction Box (RTV Application type Ⅰ)........................................5
3.2.4.2 Adhesive Application Procedure.......................................................................................5
3.2.5 Final Assembly Process Using.............................................................................................6
3.2.4.3 3.2.5.1 Preparation Attach Junction Box (RTV Application type Ⅱ)......................... 6
3.3 Wiring the Junction Box........................................................................................................................ 8
3.3.1 For Soldering Tapy Junction Box....................................................................................... 8
3.4 POTTING................................................................................................................................................9
Figure 8...............................................................................................................................................9
3.5 Junction Box Lid Assembly..................................................................................................................10
3.6 Cable Routing......................................................................................................................................11

Z8X-UM01 Rev.A
INSTRUCTION MANUAL
Zerun Co., LTD
( No.16 Yaxi Road, Zhixi Town, Jintan District, Changzhou City, 213251 Jiangsu , China )
1
1. Scope
This specification contains guidelines for the assembly, installation and fitting of the Z8X Solar
connecting boxes, and connection parts to customer solar panels.
2. Product Characteristics
2.1 ProductSpecifications
Rated System Voltage
TUV：1000V/1500V DC
UL：1000V/1500V DC
Rated Impulse Voltage
12KV/16KV
12KV/16KV
Rated Current
22A for Z8-abcd Z8-abcd (b=B; c=D);
24A for Z8-abcd Z8-abcd (b=A; c=E);
25A for Z8-abcd (c=P);
30A for Z8-abcd (c=N);
35A for Z8-abcd (c=X)
Reverse Current
40A
Application class
Class A
Over voltage category
I / II / III / IV
Conductor Size
1x4.0mm²
Protection Degree
IP65/IP68(1m,1h)
Temperature Rage
-40℃~+85℃
Pollution degree
1 / 2 / 3 / 4 (after potting)
Bus ribbons size
Width: 2.0mm ~ 8.0mm,
Thickness: 0.2mm ~ 0.5mm
Flame Resistance
5VA
Insulation Material
110C for PPE+PS, PX9406P(f1)(IT) (rely on the
material sheet provided by manufacturer)
Max. working (module) voltage
135V
Intented for Module Type
Crystalline
No. of Diodes
3
No. of Boxes
3
Material of contact rails
Copper alloy
Connection Method
Soldering / Resistance welding-type
Waterproofing Structure
Potting
Munting Type
Adhesive

Z8X-UM01 Rev.A
INSTRUCTION MANUAL
Zerun Co., LTD
( No.16 Yaxi Road, Zhixi Town, Jintan District, Changzhou City, 213251 Jiangsu , China )
2
Figure 1
2.2 Features
 Triple boxes, mini size, slim.
 With cable holder on box ,fantastic cable wiring for module automation.
 Full potting design, meet IP65/IP68(1meter, 1hour).
 Low heat generation, low power consume.
 Low cost with high performance, more competitive.
 Has soldering type and resistance welding type for choice.
 First time to use resistance welding to connect box and foil ,NO soldering failures.
 Compliance with the latest TUV and L standards, current up to 35A, system voltage up to 1500V.

Z8X-UM01 Rev.A
INSTRUCTION MANUAL
Zerun Co., LTD
( No.16 Yaxi Road, Zhixi Town, Jintan District, Changzhou City, 213251 Jiangsu , China )
3
2.3 Product Family
Z8- a b c d
Part number example – Z8-XAXO
Split type Junction Box Assembly, 3 modular diodes ,foil connection type is resistance
welding,rated current 35A,1500V certification.
Picture
Figure 2
2.4 Related Documents
 Customer Drawing Z8X_CD01/Customer Drawing Z8X_CD02
 Data Sheet Z8X_DS01
System voltage：- K：1000V；- O：1500V
Rated Current: - D：22 A（b=B）；- E：24 A(b=A)；
- P：25A；- N：30A；- X：35 A；
Structure：
- A：resistance welding type
- B：soldering
J-box Series：- Z8: Traditional Triple potting J-Box
Diode & Rails：- X：3 modular diodes

Z8X-UM01 Rev.A
INSTRUCTION MANUAL
Zerun Co., LTD
( No.16 Yaxi Road, Zhixi Town, Jintan District, Changzhou City, 213251 Jiangsu , China )
4
3. User Instruction
3.1 Cleaning
Any type of exposure to contaminants (dust, humidity etc.) can negatively affect the system with regards
to its functions, over the duration of use. This applies especially to the functionality of the connector seals
and crimped contact connections. Therefore, during assembly, it is necessary to ensure a careful and
clean processing environment.
During storage, transportation and installation, it is necessary to protect the non-inserted contacts
against contamination from dust or moisture. Connectors should be protected with the appropriate
recommended dust caps* prior to being fully connected.
* Suitable protective covers are available for connectors.
Articles which can erode the plastics (connector and Junction Box) must not be used to clean the
products. We recommend the use of soft cloths moistened with isopropyl alcohol for cleaning.
Unplugged terminal points must be protected against moisture,
dust and any environmental pollution. Only clean and
dryplugged terminal points fulfill their respective pollution
class.
3.2
Installation Guidelines for the Junction Box Attachment to the PV Modules
The following application technical instructions are made as guidelines. These instructions do not
excuse the user or installer of the Z8X boxes from independently testing the adhesive tapes or silicone
glues to determine the suitability for their proposed assembly process and application.
3.2.1 Content
This section describes the gluing of Z8X connecting boxes onto the rear side of the solar modules with
the goal to secure the product in accordance with this specification.
3.2.2 Equipment
The recommended adhesive is typically provided in cartridges. Refer to supplier’s application
instructions for adhesive applicator and application.
 Guns for spraying from the cartridge
 Gloves, soft and clean cloths
 Cleaning product isopropyl alcohol
 Spatula, brush
 Weight, for example a piece of metal with an approximate weight of 1kg

Z8X-UM01 Rev.A
INSTRUCTION MANUAL
Zerun Co., LTD
( No.16 Yaxi Road, Zhixi Town, Jintan District, Changzhou City, 213251 Jiangsu , China )
5
3.2.3 Safety Instructions
Before beginning the junction box attachment process, obtain, review and follow the manufacturer’s
material safety information.
The use of appropriate gloves and eye protection is required throughout
the attachment process. Ensure adequate ventilation at all times during
the attachment process. Refrain from eating, drinking or smoking in the
vicinity. Do not expose to open flames.
When working with silicone adhesive:
 Avoid contact with eyes. If eye contract occurs, rinse for a period of 15 minutes and seek
medical help.
 Avoid prolonged contact with skin.
3.2.4 Assembly Process
3.2.4.1 Preparation Attach Junction Box (RTV Application type Ⅰ)
Place the photovoltaic panel face down on the work table. The attachment area of the photovoltaic
panel must be dry, oil-/fat-free and free of any dust, oil and contaminants. Thoroughly clean the
attachment area with a clean, lightly moistened Isopropyl alcohol soft cloth (e.g. moistened using a
dosing unit). Further auxiliary or other cleaning agents are not permitted. Use of any other cleaning
agents has to be specified and tested by the customer. The attachment area must be free from
condensation and moisture.
To improve adherence, junction boxes may be treated with primer. The attachment area should be
thoroughly covered with primer by using a small spatula brush. The specification from the supplier of the
primer has to be followed.
Bend the photovoltaic panel foil tabs so that they extend perpendicular from the plane of the panel.
3.2.4.2 Adhesive Application Procedure
Before applying the adhesive, it is recommended that the junction box lid be opened to ease later
attachment to the solar panel. 8mm～12mm wide and 3mm ~ 5mm high band of adhesive applied to
the area which as shown in Figure 3 is adequate. During this process, Ensure that the silicon bead is
continuous and free of gaps.

Z8X-UM01 Rev.A
INSTRUCTION MANUAL
Zerun Co., LTD
( No.16 Yaxi Road, Zhixi Town, Jintan District, Changzhou City, 213251 Jiangsu , China )
6
Figure 3
To attach the junction box to the photovoltaic panel, thread the foil tab through the openings in the
bottom of the junction box. Make sure the junction box is properly oriented in a horizontal position
before firmly placing the junction box into its final position on the photovoltaic panel. Then, the 1kg
metal weight can be applied to the top of the junction box to ensure adequate adhesive coverage.
If needed, use the spatula to smooth any excess silicon that may have extruded out of the joint. Keep
the photovoltaic module assembly in the horizontal until full cure is obtained.
A full cure requires 24 hours at room temperature before the photovoltaic module can be connected and
tested.
Touching or handling of the foil tabs during the pressing of the box is not
permitted.
Mechanical stressing of foil tabs can cause their destruction
and thereby the malfunction of the panel.
3.2.5 Final Assembly Process Using
3.2.4.3 3.2.5.1 Preparation Attach Junction Box (RTV Application type Ⅱ)
Place the photovoltaic panel face down on the work table. The attachment area of the photovoltaic
panel must be dry, oil-/fat-free and free of any dust, oil and contaminants. Thoroughly clean the
attachment area with a clean, lightly moistened Isopropyl alcohol soft cloth (e.g. moistened using a
dosing unit). Further auxiliary or other cleaning agents are not permitted. Use of any other cleaning
agents has to be specified and tested by the customer. The attachment area must be free from
condensation and moisture.
To improve adherence, junction boxes may be treated with primer. The attachment area should be
thoroughly covered with primer by using a small spatula brush. The specification from the supplier of the
primer has to be followed.
Bend the photovoltaic panel foil tabs so that they extend perpendicular from the plane of the panel.
3.2.5.2 Adhesive Application Procedure
Before applying the adhesive, it is recommended that the junction box lid be opened to ease later attachment
to the solar panel. The sealant 8mm ~ 12mm wide and 3mm ~ 5mm high is evenly extruded and distributed on
the photovoltaic module. During this process, Ensure that the silicon bead is continuous and free of gaps.
Shown as Figure 4 below.

Z8X-UM01 Rev.A
INSTRUCTION MANUAL
Zerun Co., LTD
( No.16 Yaxi Road, Zhixi Town, Jintan District, Changzhou City, 213251 Jiangsu , China )
7
Figure4
To attach the junction box to the photovoltaic panel, thread the foil tab through the openings in the
bottom of the junction box. Make sure the junction box is properly oriented in a horizontal position
before firmly placing the junction box into its final position on the photovoltaic panel. Then, the 1kg
metal weight can be applied to the top of the junction box to ensure adequate adhesive coverage.
If needed, use the spatula to smooth any excess silicon that may have extruded out of the joint. Keep
the photovoltaic module assembly in the horizontal until full cure is obtained.
A full cure requires 24 hours at room temperature before the photovoltaic module can be connected and
tested.
Touching or handling of the foil tabs during the pressing of the box
is not permitted.
Mechanical stressing of foil tabs can cause their destruction
and thereby the malfunction of the panel.

Z8X-UM01 Rev.A
INSTRUCTION MANUAL
Zerun Co., LTD
( No.16 Yaxi Road, Zhixi Town, Jintan District, Changzhou City, 213251 Jiangsu , China )
8
3.3
Wiring the Junction Box
3.3.1 For Soldering Tapy Junction Box
Make sure the polarities of foil tabs from solar module keep conformity with that of junction box,
reference length of the foil tab is 12mm from the conductive contact as shown, see Figure 5.
Figure 5
Bend the bus strip and use tin soldering to connect the bus bar to the conductive plate, see Figure 6.
Set the soldering iron head temperature to ≤330 degrees. Iron heating contact rails for about 4 seconds till
the solder is totally melted, then take iron away. For quality control, this process shall only be operated by
mechanical equipment. After that, immediately use tweezers or other tools to hold the foil tab for about two
seconds.
Check and make sure every foil tab was fixed well with the contact rail.
Note: If bus bars too high, press down all of the bus bars.
Figure 6
3.3.2 For Resistance Welding Tapy Junction Box
Resistance welding junction box pitch is 21mm,before attach
the box,make sure the foil is adjusted to meet this
requirement

Z8X-UM01 Rev.A
INSTRUCTION MANUAL
Zerun Co., LTD
( No.16 Yaxi Road, Zhixi Town, Jintan District, Changzhou City, 213251 Jiangsu , China )
9
Note that the polarity of junction belt and outlet position are consistent with that of junction box.
The bus bar is connected to the module diode by resistance welding with an electrode.Below picture
show the defeil.
Figure 7
All the wiring steps shall be going with the operators wearing
anti-static gloves.
Note: After welding,bus hight must lower than diode tongue piece,or must be trimmed
3.4
POTTING
Place the model horizontally, then pour the potting glue evenly into the junction to the overflow
surface ,as picture 8.
Figure 8
ntion: During the potting, Make sure all the conductors be covered!
A full cure requires 24 hours at room temperature before the photovoltaic module can be connected and
tested.

Z8X-UM01 Rev.A
INSTRUCTION MANUAL
Zerun Co., LTD
( No.16 Yaxi Road, Zhixi Town, Jintan District, Changzhou City, 213251 Jiangsu , China )
10
3.5 Junction Box Lid Assembly
Close the Box: After potting, Cover the junction box by pressing the lid into the housing until snaps
hold the lid firmly.
Figure 9 Figure 10
Figure 11
Open the Box: To open the lid , the tip of a screwdriver having a 3 to 5 mm flat blade must be inserted
into the corresponding slot of the lid, see Figure 13, and then pushing the screwdriver evenly and slightly
until the snap get loose, see Figure 14. then remove the Lid carefully.
Figure12 Figure 13
Figure 14
Do not open the junction box while it is under an electrical load.
Components within the junction box may be electrically charged
and capable of inflicting severe injury or death.
Extreme caution should be applied when opening the junction box.
For protection against injury by electrical current, the box and the connector must always be completely
separated from other sources of voltage during the prefabricating and cannot be connected or
disconnected under voltage. All the openings in the casing must be entirely closed.
Attention: The junction box should only be opened by authorized and
trained personnel.

Z8X-UM01 Rev.A
INSTRUCTION MANUAL
Zerun Co., LTD
( No.16 Yaxi Road, Zhixi Town, Jintan District, Changzhou City, 213251 Jiangsu , China )
11
3.6 Cable Routing
The cable must not be bent or crushed on the direct exiting. A minimum bending radius R ≥ 5 x cable
diameter must be maintained. The cable must be routed in a way that tensile stress on the conductor
or connections is prevented.
Figure 15