FPE Fischer GmbH - Zonetech JB FPE eng 200907.pdf · 1996 1996 FPE is awarded the STS-Certificate No.6 (ship to stock) from Siemens Telecommunication. 19971997 In the year of the

FPE Aluminium Junction Box Page 1

FPE Fischer GmbH

Aluminium Junction Box for Photovoltaic Modules


Optimal power outputOptimal power outputOptimal power outputOptimal power outputof the solar module of the solar module of the solar module of the solar module

over its entire life time over its entire life time over its entire life time over its entire life time

FPE Aluminium Junction Box

Extreme resistanceExtreme resistanceExtreme resistanceExtreme resistance in a harsh lifelong ambient due to aluminium

Corrosion free contactsCorrosion free contactsCorrosion free contactsCorrosion free contacts due to a PTFE pressure vent

Up to 8x increased life timeincreased life timeincreased life timeincreased life time due to cooled down diodes

No fire hazards No fire hazards No fire hazards No fire hazards due to non-flammable design


Cooled down diodesOptimal heat dissipation due to Optimal heat dissipation due to Optimal heat dissipation due to Optimal heat dissipation due to

aluminiumaluminiumaluminiumaluminium heat sink:heat sink:heat sink:heat sink:• Integration of two normally

opposite processes: the optimiseddissipation of heat and the fulfillment of the required electrical insulation

• Electrical insulation is provided by heat dissipating silicone rubber tubes around the diodes (insulation up to 10.000 V)

• Safety Class II and certified according to IEC 61215 2nd Ed.


The diodes operate far below their specific temperature limit

Diodes in a plastic junction box always operate at the limit!

Diodes in an AluminiumJunction Box operate at 60%60%60%60% of their specific temperature limit

Every day … for over 20 years … for over 7.300 days!With the Aluminium Junction Box you are far below the limit!

Aluminium Junction Box at 8A (red)Plastic Junction Box at 8A (blue)

(according to IEC 61215, 2nd Ed.)


Ambient resistance due to Aluminium

• Aluminium does not become brittle over time, which allows the box to remain IP 67 over its entire lifetime

• Aluminium acts as a heat sink and allows for the cooling of the diodes

• Aluminium creates a natural protective coating due to surface oxidation. This guarantees the resistance of aluminium against environmental conditions

• Aluminium does not deform, which allows the Aluminium Junction Box to be opened and closed anytime for service purpose

• Aluminium is not flammable


No corrosion = optimal power output

• A PTFE membrane enables humidity to stay out of the Aluminium Junction Box, avoids long-term contact corrosion and maintains an optimal air pressure towards the lamination (IP 67)

• Creeping corrosion will increase the resistance of the electrical parts and reduce the power output of the PV module. In the worse case corrosion will lead to arcing inside the junction box, which drastically increases the fire hazard

• Picture 1 shows an Aluminium Junction Box that underwent 5x the required IEC damp/freeze test (5x 10 cycles)

• Picture 2 shows no corrosion inside the Aluminium Junction Box

Picture 1

Picture 2


No corrosion = no arcing

= NO FIRE HAZARD


FPEAL005

• The diodes are thermally decoupled from the solar module and are therefore able to dissipate the heat in all directions.

• Using plastic covered lead frames: Besides reducing the size of the box, the lead frames have the ability to better resist large temperature changes than simple circuit boards.

• The diodes can easily be replaced


Plastic covered lead frames


Plastic covered lead frames


Box is mounted in an automatedprocess with a closed lid


Automated mounting

• In order to have a defined position of the ribbons, a positioning block is placed (tape) on the module

• The ribbons will be slightly stamped and placed on the positioning block


Automated mounting

• Mounting the box is very simple: the ribbons are brought into an ideal position by a positioning block.

• The aluminium junction box is mounted with the pre-assembled and closed lid and the ribbons are connected automatically via metal clips.

• Alternatively, the box can be connected by soldering or welding the ribbons (with open lid only).


Automated mounting


Automated mounting


Blister for automated flash-test and cable handling


Additional pictures


Additional pictures


FPE Aluminium Junction BoxFPEAL001

Dimension 107 x 110 x 30 mmRated current 16 AMaximal current* 13 ATest current* 16,25 ARated voltage/ 1000 V DCProtection type** IP 67Safety class Class IIConnecting capacity 4-6 mm²Flat cable 3-6 mmOperating temperature range -40°C to +85°CDiode 3 Schottky diodes*IEC 61215, 2ndED. “Bypass-Diode Test”**max 1.0m/30min



Dimension 150 x 131 x 30 mmRated current 16 AMaximal current* 14 A/12 ATest current* 17,50 A/15 ARated voltage/ 1000 V DCProtection type** IP 67Safety class Class IIConnecting capacity 4-6 mm²Flat cable 3-6 mmOperating temperature range -40°C to +85°CDiode 3/4 Schottky diodes*IEC 61215, 2ndED. “Bypass-Diode Test”**max 1.0m/30min


FPE Aluminium Junction BoxFPEAL003/3 Compact

Dimension 150 x 131 x 25 mmRated current 16 AMaximal current* 12,5 ATest current* 15,60 ARated voltage/ 1000 V DCProtection type** IP 67Safety class Class IIConnecting capacity 4-6 mm²Flat cable 3-6 mmOperating temperature range -40°C to +85°CDiode 3 Schottky diodes*IEC 61215, 2ndED. “Bypass-Diode Test”**max 1.0m/30min


FPE Aluminium Junction BoxFPEAL003/4 Compact



FPE Aluminium Junction BoxFPEAL003/6 for UMG Modules




Dimension 147 x 150 x 27 mmRated current 16 AMaximal current* 16 ATest current* 20 ARated voltage/ 1000 V DCProtection type** IP 67Safety class Class IIConnecting capacity 4-6 mm²Flat cable 3-9 mmOperating temperature range -40°C to +85°CDiode 3 Schottky diodesAutomated assembly Clips or Soldering*IEC 61215, 2ndED. “Bypass-Diode Test”**max 1.0m/30min



Dimension 109 x 90 x 17mmRated current 10 AMaximal current* 10 ATest current* 12,50 ARated voltage/ 1000 V DCProtection type** IP 67Safety class Class IIConnecting capacity 2,5 – 4,0 mm²Flat cable 3-9 mmOperating temperature range -40°C to +85°CDiode 1 Schottky diodeAutomated assembly Clips*IEC 61215, 2ndED. “Bypass-Diode Test”**max 1.0m/30min


Reference

Asola GmbHSunage SALinuoEging Solar ERA SolarSunlinkQuoncion DongguanSolarShangpin Solar CNPV NESL Gloria SolarChint Solar Dengtai New Energy Ninghai Risen Electric Co.Wuxi Erquan Solar Energy Jiangyin Hareon Power Co.

SUNWORX GmbHIBC SOLAR AGILB Helios AGConti Solar GmbHSolpower AGLuxor Solar GmbHSOLEOS Solar GmbHSchoneau AGEnerquinn GmbHSunworks GmbHSunblu GmbHect GmbH Schosser Systems PVmany more …


Special Projects

• ISET Kassel: Development of an inverter integrated in a FPE Aluminium Junction Box

• Antarctic Project - Company Droben: Tests run in the ESA Laboratory for the Princess Elizabeth Station – passed environmental test at minus 70°C

Quelle: ISET – PV-MIPS Quelle: Droben


FPE exists for more than 30 years

1977 1977 1977 1977 Ulrich Fischer founds FPE Fischer GmbH. The company: development, technical consulting and sales of mechanical and electronic components.

1982198219821982 Further development of the sales in PCBs and electric parts.

1995199519951995 Ulrich Fischer co-founds EKL AG, which becomes very successful in the development and sales of CPU coolers.

1996 1996 1996 1996 FPE is awarded the STS-Certificate No.6 (ship to stock) from Siemens Telecommunication.

1997199719971997 In the year of the 20th anniversary awarded the ISO 9002 standard.

2004200420042004 Ulrich Fischer sells his shares in EKL AG and returns as Managing Director to FPE.

2005200520052005 Begin of development of new technologies for liquid cooling and solar components.

2007200720072007 Thomas Hoffmeister joins as new shareholder and Managing Director.


FPE-Fischer GmbHSteinbeisstrasse 588299 LeutkirchGermany

Tel +49 7561 9814 0Fax +49 7561 9814 50www.fpe-fischer.com

Documents

FPE Fischer GmbH - Zonetech JB FPE eng 200907.pdf · 1996 1996 FPE is awarded the STS-Certificate No.6 (ship to stock) from Siemens Telecommunication. 19971997 In the year of the