This specification covers the requirements for application of SOLARLOK Z-Rail junction box onto a photovoltaic (PV) solar panel. Each junction box consists of a base (with or without standoffs), lid, plug connector cable assembly and socket connector cable assembly or no connector cable assembly for connectorized version. The junction box is available in 2 types: foil clamp and welded. The foil clamp junction box features a serrated interface tab and requires foil clips (available separately) to terminate the junction box to the solar panel. The welded junction box features a flat interface tab (no serrations). When corresponding with personnel, use the terminology provided in this specification to facilitate your inquiries for information. 

The base features an open area, 4 contact rails,3 diodes or 3 contact rails,2 diodes. Each contact rail provides interface tabs for terminating the foil tabs of the solar panel. The open area allows the foil tabs to reach the interface tabs while maintaining a seal between the junction box and solar panel. Each diode features 2 legs that support it in place on the contact rails. Damaged diodes can be replaced. The back of the base features an attachment area used in mounting the junction box onto the solar panel. The lid features an O-ring that, when the lid is closed, ensures a tight seal. The lid has attachment tabs and latches. The latches ensure that the lid is locked and requires an instrument (such as a flat blade screwdriver) to release the latches.

NOTIFICATION:

The application of the JB Connectivity JB rail junction box on the solar panel as well as the installation of the solar panel is not part of the scope of services offered by  In addition, JB  does not offer a warranty for the Atakale Z-rail junction box with integrated solar cable assemblies if those cable assemblies will be exchanged or unfixed after delivery from JB . A cable extension has to be made at the coupling end of the cable (plug connector) and only with  components. If single connectors without attached cable are delivered by JB, the mounting of the cable is also not in the scope of services offered by . This is also the case for subsequent mounting or replacing diodes 2.

REFERENCE MATERIAL

Revision Summary Initial release of application specification 2.2. Customer Assistance Reference Product Base Part Number 2270178(Omega Clip),2270176(S-clip),2270267(welding version) for representative of Rail junction box. Use of these numbers will identify the product line and expedite your inquiries through a service network established to help you obtain product and tooling information. Such information can be obtained through a local Representative or, after purchase, by calling PRODUCT INFORMATION at the number at the bottom of page 1.

Drawings

Customer Drawings for product part numbers are available from the service network. If there is a conflict between the information contained in the Customer Drawings and this specification or with any other technical documentation supplied, calls PRODUCT INFORMATION at the number at the bottom of page 1 2.4. Specifications Product Specification 108-2471-1 provides approved product performance and test results for JB Z-Rail product line. Application Specification 114-18488-1 provides product description and application requirements for Solarlok connector. Application Specification 114-94061-1 provides product description and application requirements for the JB contacts. Application Specification 114-137077 provides product description and application requirements for the PV4-S connector

PV Solar Panel Before installing the junction box onto the solar panel, the following requirements apply: 1. The installation procedure described in this document may be used on either glass or glass with Tedlar polyvinyl fluoride (PVF) laminate substrate solar panels. 2. The attachment area (located on the bottom) of the solar panel must be dry, oil-free, fat-free, and free of any dust, oil, and contaminants. The attachment area must be thoroughly cleaned using a soft cloth lightly moistened (for example, by using a dosing unit) with isopropyl alcohol. Auxiliary and other cleaning agents must be tested by the customer and proven suitable for use on the solar panel and junction box before being used. The attachment area must be free of condensation and moisture. 3. The foil tabs must be bent so that they extend perpendicular from the surface of the solar panel.

Connectors

The mating face of each connector must be protected from contaminants (such as moisture, dust, humidity, environmental pollution, etc.). It is recommended that a suitable dust cover be installed onto each unplugged connector. Connectors must be kept clean and dry. 

Cleaning

Any type of exposure to contaminants (such as moisture, dust, humidity, environmental pollution, etc.) can negatively affect function of the junction box over the duration of use. This especially applies to connector seals and terminated connections. The environment of the area for installation and assembly must be clean and dry. The junction box, cable assembly, and connectors should be cleaned using a soft clean cloth moistened with isopropyl alcohol. In case the customer decide to clean the surface with Isopropanol he have to check with the supplier of this cleaner what time is necessary for the next process step, mean what time is defined till really all Isopropanol is removed and no longer “pollute” the surface. (And have may negative impact to the sticking of Silicone or tape). Cleaning products that can erode the plastic parts of the connectors and junction box must not be used. Oils or lubricants of any type other than mentioned in this document must not be used on or around the junction box. It is recommended that the mating face of each connector be protected by a suitable dust cover until the connector is connecte

Preparation (Optional)

The attachment area of the junction box can be thoroughly covered by primer (this will improve adherence capability). The primer can be applied using a small spatula brush. Application of the primer must be in accordance with supplier instructions. C. Mounting 1. JB  junction boxes can be mounted with the connectors in either upwards or downwards directions when the solar panel is expected to be operating under normal environmental conditions. To ensure the JB and connectors are fully protected from adverse environmental conditions JB  recommends that the Junction box is mounted with the connectors facing downwards. 2. When applying the silicone sealant or double sided adhesive tape to mount the junction box to the solar panel, it is recommended that the junction box remains open and the junction box cover is not attached.

 A 7- to 10-mm wide band of the silicone sealant must be applied to the attachment area (located on the bottom) of the base (shown in Figure 1). The band must be continuous and free of gaps. If desired, the band 114-13303-1 Rev.E1 5 of 18 may be smoothed using a small spatula or brush to ensure a uniform and gap-free application. 4. The junction box must be placed onto the attachment area of the solar panel with the foil tabs of the solar panel routed through the back of the open area of the junction box. 5. The junction box must be oriented horizontally, then be pressed onto the solar panel until it is secure. The diodes, diode legs, and contact rails must not be handled or pressed when securing the junction box to the solar panel. To ensure adequate silicone sealant coverage in the attachment area, a 1-kg [2-lb] metal weight can be positioned on the top of the closed lid of the junction box.

Silicon gel use guide

Shown as the picture, the contacted region of the silicon gel is suggested to be around the guide line in 6mm, the width of the contacted region should be bigger than 6mm, the suggested height of the silicon gel on the bottom of the box is 3.5-5 mm. And the silicon gel need to overflow out of the edge of the box for about 2-4mm, the height of the silicon gel must be higher than 1.5mm.