Safety Instructions
⚡ Warning: Work must not be carried out on live or energized parts.
⚠️ The end product and user must ensure protection from electric shock.
? For further technical data, please refer to the product catalogue.
The assembly and installation of Stäubli products must only be performed by qualified and trained specialists, adhering to all applicable safety regulations.
Stäubli Electrical Connectors (Stäubli) disclaims all liability for damages resulting from non-compliance with these warnings.
Use only Stäubli-specified components and tools. Do not deviate from the described preparation and assembly procedures, as this may compromise safety and technical data conformity. Do not modify the product in any way.
Connectors not manufactured by Stäubli, even if compatible with Stäubli elements, may not meet safety requirements for long-term stable electrical connections and must not be mated with Stäubli elements. Stäubli is not liable for damages caused by mating non-approved connectors with Stäubli elements.
Plug connections must not be disconnected under load. Plugging and unplugging while live is permitted.
The plug connectors are watertight (IP protection class) but not suitable for continuous submersion. Do not place them directly on roof membranes.
Unmated connectors must be protected from moisture and dirt using sealing caps (MC4 Article No. 32.0716 for sockets, 32.0717 for plugs). Do not mate soiled connectors.
The plug connection must not be subjected to continuous mechanical tension. Secure cables with cable binders.
Stäubli does not recommend PVC cables or untinned H07RN-F cables.
PV test plugs are primarily intended for indoor use (test laboratories, production halls).
Tools Required
| Illustration | Description | Type / Details | Order No. |
|---|---|---|---|
| (ill. 1) | Stripping pliers | Includes built-in wire stripping blade and hexagonal screwdriver A/F 2.5mm. For cable cross-section: 1.5/2.5/4/6mm². | PV-AZM-1.5/6 32.6027-156 |
| (ill. 2) | Crimping tool | MC3 crimping tool, includes locator and built-in crimping insert. Crimping range: 2.5/4/6mm² (14/12/10AWG). | PV-CZM-16100 32.6020-16100A |
| (ill. 2) | Interchangeable crimping inserts | Includes hexagonal screwdriver A/F 2.5mm. | PV-ES-CZM-16100 32.6021-16100 |
| (ill. 3) | Open-end spanner | 1 Set = 2 pieces. | PV-MS 32.6024 |
| (ill. 4) | Socket wrench insert | For tightening. | PV-WZ-AD/GWD 32.6006 |
| (ill. 5) | Socket wrench insert | For securing. | PV-SSE-AD4 32.6026 |
| (ill. 6) | Test plug | PV-PST 32.6028 |
|
| (ill. 7) | Open-end spanner | A/F 15mm. | |
| (ill. 8) | Torque screwdriver | A/F 12mm. |
Assembly
Cable Preparation
Cables with Class 5 and 6 strand construction can be connected.
Note: Use tinned conductors. Stäubli solar cables feature high-quality, tinned conductors.
(ill. 9) Cables with conductor cross-sections from 2.5mm² – 4mm² (14-10AWG) can be connected. Ensure the test plug/socket type matches the cable diameter (A):
- PV-K...T4/...6I: Cable diameter range 3mm – 6mm
- PV-K...T4/...6II: Cable diameter range 5.5mm – 9mm
(ill. 10) Strip cable insulation: Remove 6mm to 7.5mm of insulation from the end of the cable. Attention: Do not cut individual strands.
? For operation of stripping pliers PV-AZM... and blade set changes, see operating instruction MA267 at www.staubli.com/electrical.
Crimping
Important: Use only the MC3 crimp insert PV-ES-CZM-16100!
(ill. 11) Steps:
- Place the metal part of the female or male coupler into the guide for the appropriate cross-section.
- Insert the wire into the crimp sleeve as far as it will go, holding it in place.
(ill. 12) Attention: All wire strands must be correctly inserted into the borehole and visible in sight hole S. The maximum distance of 1mm must not be exceeded.
(ill. 13) Step 3: Completely close the crimping tool. Step 4: Visually check the crimp.
? For crimping tool operation, see MA251 at www.staubli.com/electrical.
Assembly Control
(ill. 14) Insert the crimped contact into the insulator of the male or female coupler until it clicks. Gently pull the lead to check that the metal part is correctly engaged.
(ill. 15) Insert the appropriate end of the test pin into the male or female coupler as far as it will go. If the contact is correctly located, the white mark on the test pin must still be visible.
(ill. 16) Hand-tighten the cable gland with PV-MS tools.
(ill. 17) Tighten the cable gland with PVWZ-AD/GWD and PVSSE-AD4 tools.
Cable Routing
Refer to cable manufacturer specifications for minimum bending radius.
Diagrams:
- "INCORRECT Routing of cable" shows a cable bent at a sharp radius.
- "CORRECT Routing of cable" shows a cable bent at a gentle radius.
Manufacturer Information
Manufacturer/Producer: Stäubli Electrical Connectors AG
Address: Stockbrunnenrain 8, 4123 Allschwil/Switzerland
Tel: +41 61 306 55 55
Fax: +41 61 306 55 56
Email: ec.ch@staubli.com
Website: www.staubli.com/electrical
