Next-Gen Solar Connectivity: Raychem RPG’s High-Performance Connectors and Junction Boxes

As the world moves toward sustainable energy, the demand for reliable and efficient solar power components continues to rise. Solar connectors and solar module junction boxes are essential components of any solar photovoltaic energy generation system, playing a crucial role in maintaining efficient electrical flow with minimal losses and ensuring the system’s long-term safety. Raychem RPG, a trusted name in electrical solutions, recently launched Solar Connectors and a Split-type Junction Box, aiming to provide reliable connections for the Solar PV market to meet the stringent demands of modern solar installations.

SOLAR CONNECTORS:

Challenges Faced-

1. Water Ingress: If connectors are not properly sealed (i.e., lacking an appropriate IP67 or IP68 rating), water can infiltrate inside the connectors, causing corrosion, short circuits, or insulation breakdown.
2. Mechanical Stress and Cable Tension: External factors such as vibrations, winds or mechanical movement and physical stress can lead to excessive pulling force on the connectors, potentially loosening or damaging the contact interfaces.
3. High Temperatures Rise: Rising temperatures can cause plastic components to degrade, seals to crack, and metal contacts to corrode, compromising the electrical connection.
4. Aging: With aging, the contact resistance of the connectors increases due to degradation of the metal contact, which can increase the voltage drop across the connectors.

Key USP’s of the Raychem RPG Solar connector to mitigate the challenges-

1. Ingress Protection: Raychem RPG’s IP 68 certified solar connector can operate for 24 hrs at one meter underwater without posing the risk of short circuiting.
2. High Pull-Out Force: Our connectors have the industry’s highest pull-out force of 350N. The connection is so secure that a special unlocking tool is necessary to properly disengage the latches.
3. Low Contact Resistance: We use the best metal contacts in the market to achieve the lowest contact resistance (0.3 mΩ) among the various connectors available.
4. Low Temperature Rise: Due to the lowest contact resistance, the temperature rise is also the lowest. Change in connector temperature (ΔT) is 24.9°C when testing in the ambient temperature range of -40°C to 85°C.
5. High Power Handling: Power handling up to UL30A // IEC 45A @ 85°C.   

JUNCTION BOX:

Challenges Faced-

1. Water Penetration: With water ingress inside the junction box, failure rates increase due to corrosion and material degradation.
2. Thermal Stability of plastic material: Junction boxes fail to handle the high temperatures and the plastic material melts.  
3. Bypass diode failure: Reasons such as dry/weak soldering, low ambient temperature handling can lead to diode bypass.

Key USP’s of the Raychem RPG Solar connector to mitigate the challenges-

1. Ingress Protection: Raychem RPG offers IP68 certified junction boxes to function accurately in harsh environmental conditions.
2. High Thermal Stability: With the use of Xyron 644z for the housing of the junction box, the relative thermal index of the housing material is 125°C, certified V0 UL-94 V0, 5VBHigh-level fire resistance to ensure safe operation.
3. Double Trench type Bypass Diode: Better thermal management due to improved current distribution. Double trench diode provide improved efficiency, higher switching rates and improved thermal management as compared to single trench diodes.
4. Low voltage drops across diode: Voltage drop of 0.51V at 60A.
5. Maximum Working Voltage: 135 V, best in industry to handle any voltage variations happening due to hot spots or cell failure.

In addition to the advantages listed above, both products are triple IEC certified (IEC 62852 for connectors, IEC 62790 for junction boxes). Furthermore, split type junction box are rated for 1500V DC applications with current capabilities of 25A, 30A, and 35A, making them suitable for large-scale solar installations.