By Admin
2025-04-01 03:36:50
Photovoltaic wiring harness waterproof connector
Waterproof grade requirements for photovoltaic connectors
- IP67/IP68 protection: Photovoltaic connectors must meet IP67 (short-term immersion) or IP68 (long-term underwater 1 meter) standards, and be suitable for outdoor rainy, humid, and sandy environments.
- Sealing structure design: The waterproof plug and connector inner hole size must be strictly matched (D4-D1 ≥ 0.3mm, D2-D3 ≥ 0.3mm) to ensure that the rubber seal fills the gap between the wire and the hole.
Electrical performance indicators
- Rated current and voltage: It is necessary to match the system requirements (such as selecting connectors with rated voltage ≥ 1500VDC and current ≥ 30A for 1500V photovoltaic systems).
- Contact resistance: ≤ 5m Ω, to avoid heat loss caused by high resistance (poor contact may cause fire)
Material and structural requirements
- Conductor material: Copper tin plated conductors are preferred to ensure conductivity and corrosion resistance.
- Insulation and sheath: PPE (polyphenylene ether) or XLPO (cross-linked polyolefin) material, temperature resistance range -40 ℃~+110 ℃, flame retardant grade UL94-V0.
Industry certification and compatibility verification
Mandatory certification standards
- UL certification: Connectors must pass UL1977 or UL6703 certification to verify flame retardancy, pressure resistance, and durability.
- IEC 62852: Photovoltaic connectors must comply with this standard and cover tests such as UV resistance and wet heat cycling.
System compatibility
- Interface matching: Priority should be given to universal interfaces such as MC4 and MC4 Evo, which are compatible with mainstream photovoltaic module and inverter brands.
- Wire diameter adaptation: Supports 2.5~6mm ² (14AWG~10AWG) cables to meet the needs of different power scenarios.
Case study of photovoltaic connector selection
| Scene | Recommended model | Core parameters | Reference standards |
| Distributed rooftop photovoltaics | MC4 Evo waterproof connector | 1500VDC/30A， IP68，UL94-V0 | UL1977、IEC 62852 |
| Desert power station | 1500V anti dust connector | Temperature resistance of 125 ℃, sand proof structure, IP68 | IEC 60529、UL6703 |
| Offshore photovoltaics | IP68 armored connector wire harness | Salt spray resistance for 1000h, stainless steel shell | iso9227、UL94-V0 |
IP68 waterproof rating test
1.Airtightness testing:
Using the air pressure method (inflation for 5 seconds → balance for 8 seconds → test for 5 seconds), the instrument directly determines the sealing performance (qualified display "PASS", leakage display "FAIL").
Key parameters: Test pressure ≥ 50kPa, holding time ≥ 24 hours, leakage rate ≤ 0.1mbar/min.
2.Actual immersion test:
Equipment status: It needs to be carried out while powered on (simulating a real usage environment).
Test conditions:
- Water depth of 1 meter, water temperature of 25 ℃± 5 ℃
- Soak for 24 hours (far exceeding the 30 minute standard of IP67)
Qualification judgment: After removal, the function is normal, there is no residual water stains inside, and the insulation resistance is ≥ 100M Ω.
