s o l a r

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Introduction

Elcom International Pvt. Ltd. is an Electro-Mechanical and Electronic (EM&E) manufacturing company known best for being the pioneers in this industry in India. Established in 1981, with its factory in Kolhapur and Headquarters in Mumbai, we are backed with more than three decades of experience and goodwill from countless satisfied customers across the world.

Today, we have transformed from components manufacturing company to a business encompassing four vertical business lines and has ISO 9001:2008 certified state of-the-art manufacturing facility and R&D facility recognized by DSIR. With our core expertise in manufacturing of EM&E components, we also now manufacture standard & intelligent Power Distribution Units (PDUs), solar components and consumer products like surge protectors.

Manufacturing and designing solar components and products is Elcom's latest additions to its repertoire. With the aim to contribute to a greener economy and to innovate and make sustainable energy available, Elcom turned into a professional manufacturer of Solar Components in the year 2013 thus becoming, India's first manufacturer of solar components.

Since its conception, Elcom has established itself at the forefront of designing & manufacturing high grade solar components which include PV connectors, module junction boxes and PV combiner box wire harness. These are widely used in all kinds of solar power applications. Elcom has an ISO 9001:2008 certified manufacturing facility and these products have been certified by TUV as per IEC standards. Elcom solar components are customized, efficient and durable like none before and all come with a 25 year guarantee of performance. In the near future, Elcom with its most reliable R&D and manufacturing team aims to launch a variety of innovative solar products. Let's join hands and become the pioneers in the solar components and products business.

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Table of Contents

Cable Connectors 1-4

Branch Connectors 5-8

Module Junction Boxes 9-10

Tools and Accessories 11

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A. Solar PV Cable Connector

PV Cable Connector (ESC-4)

PV Cable Connector with safety Window (ESC-4-UW)

PV Panel Mount Connector(ESC-4-PM)

Salient Features

• India’s first manufacturer of Solar PV connector

• MC- 4 Compatible

• Suitable cable cross section area 4 sq.mm & 6 sq.mm

• TUV approved as per EN 50521:2008

• Quick, easy and Safe snap

• IP68 – High class protection

• Temperature range : -40°C to +85°C

• Contact resistance <0.5 m-ohm.

• Contact material Copper with silver plating.

• Silver plated Beryllium Copper (BeCu) contact spring to achieve lower contact resistance.

• Engineering plastic, UV complaint and flame resistant apt for outdoor application.

• Suitable for Solar PV field installations and for direct connection to module junction box

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Exploded view with description

End cap: End cap holds the entire connector assembly. End cap is made from PPO (polyphenylene oxide)

material. It is best suited for outdoor application.

Grommet: Grommet makes available a reinforced hole through which the solar cable passes through. It helps

the cable to remain in place and allows firm tightening of the end cap. Grommet is also made from PPO

(polyphenylene oxide) material.

Rubber gasket: Rubber gasket avoids entry of dust and water inside the connector assembly. Thus, rubber

gasket maintains the IP68 degree of protection. The gasket is made from Silicone, FR grade material.

Spring retainer: Once the cable is crimped in the plug/socket contact, it is the function of spring retainer to

provide firm grip to crimped contacts inside the connector assembly.

Plug/Socket contact: These are the current carrying parts of the connector. These are fully silver plated

copper contacts. Elcom solar PV connectors achieve contact resistance of < 0.5 m-ohm.

Plug/Socket housing: This PPO (polyphenylene oxide) housing houses the current carrying contact parts.

Made from PPO (polyphenylene oxide) material is best suited for outdoor application and is UV resistant.

Spring collet: This spring plays a very important role in achieve better conductivity and reduce losses. Spring

collect is inserted inside the socket contact. The material used is silver plated Beryllium Copper (BeCu) that

helps achieve lower contact resistance.

Grommet Spring retainer

Plug housing

Spring collet

Plug contact

Socket housingSocket contactGasketEnd cap

End cap

Grommet

Gasket

Spring retainer

2

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36.20

Ø18.7x2n.

Ø4.00

ESC-4-ML

34.4

ESC-4-F L

+0.127.2 -0.10

a. PV Cable connector (ESC-4)

b. PV Cable connector with safety window (ESC-4-UW)

Ordering Code :

Ordering Code : Wire Length (L)

As per CustomerRequirment

Solar PV Connector

ESC-4-MESC-4-F

Wire Type

A 4 Sq.mm

B 6 Sq.mm

C 2.5 Sq.mm

Wire Color

03 Black04 Red

Wire Length (L)

As per CustomerRequirment

Solar PV Connector

ESC-4-UW-MESC-4-UW-F

Wire Type

A 4 Sq.mmB 6 Sq.mm

Wire Color

03 Black04 Red

Specification Table

SR. NO PARAMETER SPECIFICATION 1 Type Ø4mm PV Connector 2 Rated current 20A, 30A. 3 Rated voltage 1000V DC 4 Test voltage 6000V AC (1min) 5 Typical contact resistance <0.5 m-ohm 6 Degree of protection (Mated) IP68 (IEC 60529) 7 Protection class II 8 Flammability class UL94U-0 9 Insulation material PPO 10 Contact material Copper, Silver Plated 11 Temperature range -40ºC~+85ºC 12 Upper limiting temperature 100ºC

2 2 2 13 Cable size 2.5mm , 4mm & 6mm 14 Rated impulse voltage 8KV

SR. NO PARAMETER SPECIFICATION 15 Application Class A 16 Pollution Degree 3 17 Over voltage category Category III 18 Relative humidity (%) 85%±5% 19 Pin dimensions Ø4.0mm 20 Stripping Length 8mm Max. 21 Insertion force (Male Female hsg.) <50N 22 Withdrawal force (Male Female hsg.) >50N 23 Sealing material Silicon rubber 24 Minimum creepage distance Contact to contact

not applicable

25 Insulation resistance >1000 MW 26 Reference standard EN-50521:2008

2 2Note: For 2.5mm wire crimping, Use Crimping tool of 4mm .

ESC-4-UW-M

36.20

Ø18.7x2

n.

L

Ø4.00

21.8

Ø24

Provision For Unlocking

ESC-4-F

34.40

L

7.2

3

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Panel Cutout

11.50

∅12.60

M12

34.4

ESC-4-PM-F

L

TUV 2PFG 1169 PV1-F

Ø4.00

M12

36

Ø19

ESC-4-PM-M

L

TUV 2PFG 1169 PV1-F

c. PV Panel Mount Connector (ESC-4-PM)

Wire Color Wire Length (L)

As per CustomerRequirment

Wire Type

A 4 Sq.mm

B 6 Sq.mm03 Black04 Red

Solar PV Connector

ESC-4-PM-MESC-4-PM-F

ESC-4-PM-UW-M

PV Panel Connector (ESC-4-PM) : Specification Table

SR. NO PARAMETER SPECIFICATION 1 Type Ø4mm, PV connector 2 Rated current 20A-30A. 3 Rated voltage 1000V DC 4 Test voltage 6000V AC (1min) 5 Typical contact resistance <0.5 m-ohms 6 Degree of protection (Mated) IP68(IEC 60529) 7 Protection class II 8 Flammability class UL94V-0 9 Insulation material PPO 10 Contact material Copper, Silver Plated 11 Temperature range -40ºC~+85ºC 12 Upper limiting temperature 100ºC

2 2 2 13 Cable size 2.5mm , 4mm & 6mm 14 Rated impluse voltage 8KV 15 Application class A 16 Pollution degree 3 17 Over voltage category Category III 18 Relative Humidity (%) 85% ± 5% 19 Pin dimensions Ø4.0mm 20 Stripping length 8mm max. 21 Insertion force (male female hsg.) <50N 22 Withdrawal force (male female hsg.) >50N 23 Sealing material Silicon rubber 24 Minimum creepage distance Contact to contact not applicable 25 Insulation resistance >1000 MW 26 Reference standard EN-50521:2008

2 2Note : For 2.5mm wire crimping, use crimping tool of 4mm

4

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Solar PanelCABLE

CONNECTOR2-WAY PLUG CONNECTOR

CABLE COUPLER

B. Solar PV Branch Connectors

PV 2-way Branch Connector PV 3-way Branch Connector

Salient Features

• Provides a quick and easy parallel wiring solution for solar panels

• MC-4 compatible

• Sealed to IP 68 and UV resistant

• Compact design

• Quick, easy assembly and allows secure gripping

• Engineering plastic, UV complaint and flame resistant apt for outdoor application.

2 WAY BRANCH CONNECTOR

Solar Panel Solar Panel

5

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a. PV 2-way Branch Connector

b. PV 3-way Branch Connector

ESC-BC-S2P1 ESC-BC-S1P2

ESC-BC-S1P3 ESC-BC-S3P1

PV 2-WAY BRANCH CONNECTOR : Specification Table PV 3-WAY BRANCH CONNECTOR : Specification Table

26

35

∅5.1

∅5.1

26

SR. NO PARAMETER SPECIFICATION 1 Type Ø4 mm, Branch connector 2 Rated current 20A-30A. 3 Rated voltage 1000V DC 4 Test voltage 6000V AC (1min) 5 Typical contact resistance <0.5 m-ohms 6 Degree of protection (Mated) IP68(IEC 60529) 7 Protection class II 8 Flammability class UL94V-0 9 Insulation material PPO 10 Contact material Copper alloy, tin plating 11 Temperature range -40ºC~+85ºC 12 Pin dimensions Ø4.0mm 14 Reference standard EN-50521:2008 15 Sealing material Silicon rubber

SR. NO PARAMETER SPECIFICATION 1 Type Ø4mm, Y branch connector 2 Rated current 20A-30A. 3 Rated voltage 1000V DC 4 Test voltage 6000V AC (1min) 5 Typical contact resistance <0.5 m-ohms 6 Degree of protection (Mated) IP68 (IEC 60529) 7 Protection class II 8 Flammability class UL94V-0 9 Insulation material PPO 10 Contact material Copper alloy, tin plating 11 Temperature range -40ºC~+85ºC 12 Suitable cable cross sec. 2.5mm2-6.0mm2 13 Pin dimensions Ø4.0mm 14 Reference standard EN-50521:2008 15 Sealing material Silicon rubber

6

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C. Solar T and Y PV Branch Connectors with cable assembly

PV 3-way Branch Connector

Salient Features

• Provides a quick and easy parallel wiring solution for solar panels

• MC-4 compatible

• Sealed to IP 68 and UV resistant

• Compact design

• Quick, easy assembly and allows secure gripping

• Engineering plastic, UV complaint and flame resistant apt for outdoor application.

PV 2-way T Branch Connector

PV 2-way Y Branch Connector

7

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Elcom

85.9 [3.38"]

12 [.47"]15

[.59

"]

50.5

[1.9

9"]

C. Solar T and Y PV Branch Connectors with cable assembly

PV 3-way Branch Connector (ESC-3BC-S3P1)

PV 2-way T Branch Connector (ESC-TBC-21D)

PV 2-way Y Branch Connector (ESC-YBC-S2P1)

Specification Table

SR. NO PARAMETER SPECIFICATION SPECIFICATION SPECIFICATION

1 Type Ø4mm, 3 branch connector (S3P1) Ø4mm, T branch connector (S1P2) Ø4mm, T branch connector (S1P2)

2 Rated current 20A-30A. 20A-30A. 20A-30A.

3 Rated voltage 1000V DC 1000V DC 1000V DC

4 Test voltage 6000V AC (1min) 6000V AC (1min) 6000V AC (1min)

5 Typical contact resistance <5m0hms <5m0hms <5m0hms

6 Degree of protection (Mated) IP67(IEC 60529) IP67(IEC 60529) IP67(IEC 60529)

7 Protection class I II II

8 Flammability class UL94V-0 UL94V-0 UL94V-0

9 Insulation material PPO PPO PPO

10 Contact material Copper alloy, tin plating Copper alloy, tin plating Copper alloy, tin plating

11 Temperature range -40ºC~+85ºC -40ºC~+85ºC -40ºC~+85ºC2 2 2 2 12 Suitable cable cross sec. 2.5mm - 6.0mm 2.5mm - 6.0mm As per ordering table

14AWG - 10AWG 14AWG - 10AWG

13 Pin dimensions Ø4.0mm Ø4.0mm Ø4.0mm

14 Cable length 0.3 meter 0.3 meter As per customer requirement

15 Reference standard EN-50521:2008 EN-50521:2008 EN-50521:2008

16 PV connector ESC-4-M (1no.) ESC-4-M (2no.) ESC-4-M (2no.)

ESC-4-F (3nos.) ESC-4-M (1nos.) ESC-4-M (1nos.)

PV 3-way Branch Connector (ESC-3BC-S3P1)

PV 2-way T Branch Connector (ESC-TBC-21D)

PV 2-way Y Branch Connector (ESC-YBC-S2P1)

Elcom

270±5 68±0.3 270±5

ESC-4-M ESC-4-F

ESC-4-F

Ø15

45°

270±5

38.9

±0.

5

Elcom

16 [.

63"]

14 [.

55"]

67 [2.64"]

62.3

[2

.45"

]

8

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C. Solar Module Junction box

2-rail Junction box

Salient Features• Available in various configurations – 2-rail, 3-rail and 4-rail

• Reliable locking mechanism

• Multi-diode options

• Flame resistant polymer (UL 94V-0 compliance)

• Ageing and UV resistant ·

• IP65 (IEC 60529) protection

• Suitable for 600V and 1000V DC systems

3-rail Junction box 4-rail Junction box

9

Rear View of Solar Module

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Specification Table

SR. NO PARAMETER ESC-JB2 ESC-JB3 ESC-JB4

1 Typical contact resistance <5m0hms <5m0hms <5m0hms

2 Rated current 3A-20A (Potting) 3A-20A (Potting) 3A-20A (Potting)

3 Rated voltage 1000V DC 1000V DC 1000V DC

4 Degree of protection (Mated) IP65(IEC 60529) IP65(IEC 60529) IP65(IEC 60529)

5 Flammability class UL94V-0 UL94V-0 UL94V-0

6 Insulation material PPO PPO PPO

7 Contact material Brass, tin plating Brass, tin plating Brass, tin plating

8 Temperature range -40ºC~+85ºC -40ºC~+85ºC -40ºC~+85ºC2 2 2 2 2 2 2 2 2 2 2 2 9 Suitable cable cross sec. 4.0mm - 6.0mm (0.16 -0.24 Inch) 4.0mm - 6.0mm (0.16 -0.24 Inch) 4.0mm - 6.0mm (0.16 -0.24 Inch)

12AWG - 10AWG 12AWG - 10AWG 12AWG - 10AWG

10 Joining of ribbon Soldering Soldering Soldering

11 Diode Qty. 1 nos. 2 nos. 3 nos.

12 Pin dimensions Ø4.0(0.16") Ø4.0(0.16") Ø4.0(0.16")

14 Cable length 1000 (0.039") 1000 (0.039") 1000 (0.039")

15 Sealing Gasket Silicon rubber Silicon rubber Silicon rubber

16 Reference standard EN-50521-2008 EN-50521-2008 EN-50521-2008

2-rail (ESC-JB2)

2-rail (ESP-JB2-E) 3-rail (ESP-JB3-E)

4-rail (ESC-JB4)3-rail (ESC-JB3)

10

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Tools and Accessories

a. Crimping tool

CT-001

Salient Features• Crimping tool for cable range 2.5 sq.mm/4 sq.mm/6 sq.mm

• Hardened and durable steel construction

• Accurate and high quality crimping

• Portable and light weight

• Perfect handle gripping position

b. Disconnect tools

CT-002 CT-003

Salient Features• For locking and unlocking of solar connector cap

• Portable

• Perfect for locking cap

• Light weight

• Easy to use

11

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Note

ELCOM INTERNATIONAL PVT. LTD.Office : 20 Prabhadevi Ind. Estate, 408 Veer Savarkar Marg, Prabhadevi,

Mumbai 400 025, India. • Tel.: +91 22 66114444 • Fax: +91 22 66114422

Factory : Elcom House, M. B. Lohia Road, 413/1/1A, Gandhinagar,Kolhapur 416 119. India. • Tel. : + 91 231 6618007 • Fax: +91 231 6618008

Email : elcom.mail@elcom-in.com, sales@elcom-in.com

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