Dongguan, China · Treasun New Energy Technology Co., Ltd.
Moulding, crimping, harness assembly and electrical test in one plant
Treasol is a solar PV connector and wire harness manufacturer in Dongguan, China. This page documents the production lines, tooling workshop and test equipment used to make its connectors, fuse connectors, diode connectors, junction boxes and harness assemblies.
The catalogue covers cable couplers (CN4U-C), panel connectors (CN4U-P), Y and T branch connectors, in-line fuse (F4C) and diode (D4A/D4B) connectors, PV junction boxes, built-to-drawing wiring harnesses, H1Z2Z2-K PV cable and assembly tools. Products are rated up to 1500 V DC with IP65, IP67 and IP68 options, and hold TÜV Rheinland, UL, CE and RoHS documentation depending on the product family.
Terminals are bought in from stamping and plating suppliers working to our drawings. Each incoming lot is checked for dimensions, plating and insertion force. Crimping, seating, overmoulding and final testing stay in-house, because those steps decide whether the joint holds.
Where this page fits: About Us covers the company and its process stages. PV connector manufacturing explains the process and the standards behind it. This page lists the equipment that does the work, for buyers who need to see what a plant has before placing an order or booking an audit.
Page last reviewed: November 2026
Eight stages, with the machine or instrument used at each one. About Us describes the process sequence itself.
Terminals, resin, seals and cable are checked against the drawing before release to the line.
Incoming gauges for dimensions, plating and insertion forceHousings, latches and sealing parts are moulded from the approved resin grade. First-off parts are measured every time a mould goes back on a machine.
Moulding machines, mould temperature controllers, hopper dryersMoulds are numbered and inspected on a fixed cycle. Worn latch or thread details are reworked before the next production run.
Mould store, toolroom, maintenance registerEach cable class has its own die set. Crimp height and width are measured with a gauge rather than judged by eye.
Crimping machines, die sets, crimp height gauges; joint validation to IEC 62852 Annex E and IPC/WHMA-A-620Seal, latch and contact are seated with fixtures that hold the geometry, so the mating face stays in tolerance.
Assembly benches, pneumatic press fixtures, seating toolsHarness joints are overmoulded. Junction box cavities are potted where the design asks for it.
Vertical moulding machines, insert fixturesWithstand voltage, continuity and polarity, contact resistance, pull-out force, salt spray and IP checks.
Withstand voltage tester, load current and contact resistance sets, force testers, salt spray and IP rigsParts are counted, bagged or reeled, and labelled with part number, quantity and batch code.
Counting and bagging station, labeller, weighing scaleSeven areas of the plant, following the order a connector or a harness passes through them.
Housings, cable nuts, locking latches and seals are moulded in-house. Moulding sits next to assembly, so a colour or resin question is settled the same day instead of waiting on a supplier sample.
Machine parameters, resin grade and colour are recorded for each run. First-off parts are measured before the batch is released.
This is the mould store. Each mould is numbered and inspected on a fixed cycle. Cores, latch details and sealing grooves are reworked in the toolroom before wear shows up in a finished part.
When a drawing changes, whether it is a cable range, a panel cut-out or a marking, the change is made on the tool and confirmed with a first-article sample.
Crimping gets its own die set per cable class, and the result is measured with a gauge for compression height and width. Pull-out force is checked on samples from the run.
Assembly uses seating fixtures so the seal and latch sit at the geometry the mould was cut for. A latch pressed a fraction high comes back as a field failure two years later.
Harness work has more terminations per item and more routing than a single connector. Leg lengths and branch positions come off the customer drawing, and the person crimping and the person testing read the same sheet.
Finished harnesses are coiled and labelled so a site electrician can match the assembly in the crate to the one on the drawing.
On harness assemblies the cable to connector joint is overmoulded instead of taped or heat-shrunk. Where a junction box design calls for it, potting compound fills the cavity around the contacts.
Both routes aim at the same thing: ingress protection that survives thermal cycling comes from a moulded or potted interface, not from a gasket that can be fitted wrongly on site.
Checks sit where a defect becomes expensive: incoming material, first-off after a mould change, crimp settings, and the finished assembly. Finished parts go through the electrical test sequence before they reach packing.
Results are recorded against the batch, so an audit can walk a carton back to the moulding run and the crimp die behind it.
Connectors are counted, bagged or reeled, and labelled with part number, quantity and batch code. Distributor and OEM orders can carry the buyer's own label and carton marking.
Packing follows the order: the same connector may ship as a loose bag for a harness shop and as a reel for an automated line.
Electrical, mechanical, climatic and ingress-protection equipment used for routine and type testing.
Test families follow IEC 62852 (2014 + AMD1:2020) and EN 62852 for connectors, IEC 62790 for junction boxes, and EN 50618 and IEC 62930 for PV cable. UL 6703 and UL 3730 apply where the certificate scope calls for them.
Applies the proof voltage across a connector, mated and unmated, to confirm the insulation holds.
Electrical
Runs rated current through a mated pair while contact temperature is monitored.
Electrical
Four-wire measurement across the crimped contact. A value that climbs is the first sign of a joint that will heat up.
Electrical
Pulls the cable out of the terminated contact to verify the crimp.
Mechanical
Neutral salt spray exposure on terminal plating, checked against the corrosion exposure the project specifies.
Climatic
Runs the 85 °C and 85 % RH damp heat condition of IEC 60068-2-78 on connectors, junction boxes and harness assemblies, to check seal, potting and housing ageing.
Climatic
Spray and immersion checks on connectors and junction boxes, including the IP68 items in the range.
Ingress protection
Continuity and fuse element check on in-line fuse connectors before packing.
Fuse connector lineInstrument models, measurement ranges and calibration certificates are not listed here. They go out with the equipment list during a factory audit, or with the quotation for a part number, because the laboratory grows as new product families are added.
Four checkpoints. Each one leaves a record that stays with the batch.
| Checkpoint | What is checked | Record |
|---|---|---|
| Incoming (IQC) | Terminal dimensions and coating to IEC 62852 and EN 62852, housing resin grade and colour, seal hardness and dimensions, cable marking and conductor size to EN 50618 and IEC 62930. | Incoming lot record linked to the supplier lot |
| In-process (IPQC) | First-off dimensions after a mould change, crimp height and width at the start of a run, seal and latch seating. | First-off sheet and crimp setting sheet |
| Final (FQC) | Withstand voltage, insulation resistance, continuity and polarity, contact resistance, pull-out force on samples, appearance against the approved sample. These are the electrical and mechanical test families called up by IEC 62852. | Electrical test result per batch |
| Outgoing (OQC) | Quantity, part number and batch label, inner packing, carton marking, documents required by the order. | Packing list and shipping label check |
One code on the carton resolves to four records.
Resin lot, machine and shift.
Die set, compression height and width.
Withstand voltage, continuity and contact resistance result for that run.
Certificate reference for the part number and the batch test record.
Records are retrieved by batch code during an audit, not by date. Certificate PDFs are supplied with quotation documents rather than published on this site.
Two scopes. One is published here; the other is confirmed per part number.
A cable coupler and a multi-leg harness do not use the same machine time or the same mould, so one plant-wide figure would mislead more than it informs. If capacity forms part of a tender requirement, say so in the enquiry and it is confirmed in writing. Request a quotation.
The questions buyers, distributors and inspection agencies ask before a plant visit.
Yes. Treasol hosts customer audits and third-party inspections at the Dongguan plant, including visits arranged by buying offices and testing agencies. Audit dates are scheduled with the sales contact handling the enquiry.
Moulding, crimping, assembly, overmoulding and all electrical and mechanical testing are carried out in-house. Terminals are purchased from stamping and plating suppliers working to Treasol drawings, and every incoming lot is inspected before release to the line.
The laboratory is equipped with a withstand voltage tester, a maximum load current test set, a contact resistance tester, a pull-out force tester, a salt spray chamber, an 85 °C / 85 % RH damp heat chamber, an IP rating test rig and a fuse tester for the in-line fuse connector line.
Yes. The equipment list with instrument models and measurement ranges is issued with a quotation or during a factory audit, together with the certificate reference applicable to the part number and the electrical test record for the batch.
Monthly capacity depends on the part number, because a cable coupler and a multi-leg harness use different machine time and different moulds. Capacity, sample lead time and production lead time are stated in the quotation for the item being sourced.
Each carton carries a batch code that resolves to the moulding run and resin lot, the crimp die and compression setting, and the electrical test result for that run. Records are retrieved by batch code during an audit.
Connector tests follow IEC 62852 (2014 + AMD1:2020) and EN 62852, with UL 6703 where the certificate scope calls for it. Junction box tests follow IEC 62790 and UL 3730, and PV cable checks follow EN 50618 and IEC 62930. Crimp joints are validated against IEC 62852 Annex E and IPC/WHMA-A-620.
The pages this factory evidence supports, and the product lines made here.
Product lines made in this plant: Solar PV connectors · Fuse connectors · Diode connectors · Branch connectors · PV junction boxes · Solar wiring harness · PV cable
Send the part number or the product family you are sourcing. We will return the equipment list, the certificate reference and the test records with the quotation. Customer and third-party audits are welcome, and buyers, distributors and inspection agencies are hosted at the plant in Dongguan.
Request the equipment list