Stäubli MA231 Assembly Instructions

Product Overview

This document provides assembly instructions for Stäubli PV connectors, specifically the PV-KST4 male coupler and PV-KBT4 female coupler, commonly known as MC4 connectors. It also covers the optional PV-SSH4 safety lock clip and PV-BVK4/PV-SVK4 sealing caps.

Images on Page 1 depict:

• PV-KBT4 Female cable coupler series (PV-KBT4/2.5, PV-KBT4/6, PV-KBT4/10, PV-KBT4/5, PV-KBT4/8II).
• PV-KST4 Male cable coupler series (PV-KST4/2.5, PV-KST4/6, PV-KST4/10, PV-KST4/5, PV-KST4/8II).
• Optional PV-SSH4 Safety lock clip.
• Sealing caps: PV-BVK4 and PV-SVK4.

For additional resources, visit www.staubli.com/re-downloads.html (refer to MA252).

Safety Instructions

Importance of the assembly instructions: Failure to follow these instructions can result in life-threatening injuries due to electric shock, electric arcs, fire, or system failure.

• Follow all assembly instructions completely.
• Connect and use the product only as per these instructions and the technical data.
• Keep these instructions for future reference and pass them on to subsequent users.

Intended use: The connector electrically connects components within the DC circuits of a photovoltaic array. It can also be used for other low-voltage DC applications, though requirements may differ.

• For more information, contact Stäubli at www.staubli.com/electrical.

Requirements for personnel: Assembly and installation must be performed exclusively by a qualified electrician or an electrically instructed person.

• An electrician has the necessary training and experience to identify and avoid electrical hazards and use appropriate protective equipment.
• An electrically instructed person is supervised by an electrician and can identify and avoid electrical hazards.

Prerequisites for installation and assembly:

• ❗ Never use obviously damaged connectors.
• ❗ Only use tools and procedures approved by Stäubli.
• ❗ Only connect Stäubli-approved PV-cables to the connectors.

Safe assembly and mounting: Live parts can remain energized even after disconnection.

• ❗ Only install the product when the photovoltaic array or string is de-energized.

Mating and disconnecting:

• ❗ Always de-energize the photovoltaic system before mating or disconnecting connectors.
• ❗ Never disconnect connectors under load.
• ❗ Never connect Stäubli connectors with connectors from other manufacturers.
• ❗ Never mate contaminated connectors.

Do NOT modify NOR repair component:

• Mount the connector only once.
• Do NOT modify connectors after assembly.
• Replace defective connectors.

Tools Required

The following tools are required for assembly:

• Illustration 1: Stripping pliers PV-AZM...

  For stripping conductors of various cross-sections (e.g., 1.5/2.5/4/6 mm², AWG 4/6/10). Model PV-AZM-156 (Order No. 32.6027-156) and PV-AZM-410 (Order No. 32.6027-410).

  ? Note: See operating instructions MA267 at www.staubli.com/re-downloads.html.

• Illustration 2: Assembly and unlocking tool

  PV-MS-PLS (Order No. 32.6058) or Open-end spanner set PV-MS (Order No. 32.6024).

  ? Note: See operating instructions MA270 at www.staubli.com/re-downloads.html.

• Illustration 3: Crimping pliers PV-CZM-6x100

  Includes locator and crimping die.

  ? Note: See operating instructions MA704 at www.staubli.com/re-downloads.html.

• Illustration 4: Crimping pliers PV-CZM-2x100

  Includes locator and crimping die.

  ? Note: See operating instructions MA251 at www.staubli.com/re-downloads.html.

Assigning Crimping Pliers Dies and Locators

Use the following table to select the correct crimping pliers die and locator based on the connector type and conductor cross-section.

* The harmonized crimping pliers shall not be used along with O-crimps for PV-KST4/5..., PV-KBT4/5..., PV-KST4/8..., PV-KBT4/8....

? Note: For open (B-Crimp) crimping die and locator information, see operating instructions MA704 at www.staubli.com/electrical. For closed (O-crimp) inserts and locators, see operating instructions MA251.

Notes on Connectors and Components Storage

Stäubli recommends storing connector components at a constant temperature between -30°C and +60°C with relative humidity below 70%. Components must not be exposed to direct moisture, condensation, or aggressive chemicals (acids, alkalis, gases, acetone). Under these conditions, the maximum storage time is two years from manufacturing.

Guideline for Connector Configuration

? Note: If the cable diameter falls between two limits, use the smaller sealing insert.

Cable Preparation

For IEC applications, use cables with flexible conductors of class 5 or 6 (IEC 60228). For UL applications, use class B conductors or higher.

❗ Attention: Use only tinned copper conductors. Do not use bare or oxidized conductors. Stäubli solar cables have high-quality tinned conductors. For safety reasons, Stäubli prohibits the use of PVC cables and non-tinned cables of type H07RN-F.

* It is acceptable to use bare copper conductors (Class B or higher) with PV-KBT4/5...-UR, PV-KST4/5...-UR, PV-KBT4/8II-UR, and PV-KST4/8II-UR.

Illustration 8: Check dimensions A (cable outer diameter) and b (control dimension) as per Table 2 and Table 3.

? Note: Contact Stäubli if using cable diameters not listed in Table 2 or 3.

Connector Configuration Verified by TÜV Rheinland

Cables connected to the connectors must be suitable for photovoltaic systems and comply with IEC 62930 requirements.

? Note: The PV cable's sheath material must meet insulation class 1 according to IEC 60664-1.

Selection of Connector Configuration when using Cables Certified at UL

Cables connected to the connectors must be suitable for photovoltaic systems and comply with ZKLA (PV-wire) or TYLZ (USE-2) requirements.

*Preferred conductor stranding: 19-65.

? Note: If the selected cable meets the criteria in Tables 2 and 3, and the technical data on page 13, it can be used as a double-certified cable (TÜV Rheinland and UL).

Illustration 9: Strip cable insulation to length 'L' as per Table 4 and check.

❗ Attention: Do not cut strands when stripping the cable!

Crimping

Illustration 10: Crimping Open Crimp Contacts (B-Crimp)

For PV-KxT4/2.5...-UR; PV-KxT4/6...-UR or PV-KxT4/10...:

• Open clamp (K) and hold tight.
• Insert the contact into the appropriate cross-section range.
• Turn the crimping flaps (C) upwards.
• Release clamp (K). The contact is now locked.

? Note: See operating instructions MA704 at www.staubli.com/re-downloads.html.

Illustration 11: Crimping Closed Crimp Contacts (O-Crimp)

For PV-KxT4/5...-UR or PV-KxT4/8II-UR:

• Place the contact into the appropriate cross-section range.
• For PV-KxT4/5... and PV-KxT4/8...: Place the contact into the appropriate locator position based on the conductor cross-section to be crimped.

? Note: See operating instructions MA251 at www.staubli.com/re-downloads.html.

Illustration 12: Ensure the contact is fully inserted into the locator before crimping. Gently press the pliers until the crimping flaps are properly located within the crimping die.

Illustration 13:

• Diagram shows distance 'x' between the crimped contact and wire insulation.
• ❗ Attention: The distance 'x' between the crimped contact and the wire insulation must be maintained.

Illustration 14: Insert the stripped cable end until the lead strands come up against the clamp. Completely close the crimping pliers.

Illustration 15: Visual Crimp Check

Visually check the crimp according to IEC 60352-2 criteria. Confirm that:

• All strands are captured in the crimp sleeve.
• The crimp sleeve is not deformed and no part of the crimp flaps is missing.
• The crimp is symmetrical.
• A "brush" of conductor strands is visible on the contact side of the crimp.

Assembly Check

Illustration 16: Insert the crimped contact into the insulator of the male or female coupler until it clicks. Pull the cable gently to verify that the metal part is correctly engaged.

Illustration 17: Insert the appropriate end of the test pin into the male or female coupler as far as it will go. If the contact is assembled properly, the white mark on the test pin must still be visible.

Cable Gland Assembly

Illustration 18:

• Pre-tighten the cable gland using PV-MS or PV-MS-PLS tools.
• Tighten the cable gland using the PV-WZ-Torque-Set while holding the insulator front with PV-MS or PV-MS-PLS.
• The tightening torque must be appropriate for the solar cables used. Typical values are between 3.4 N m and 3.5 N m.

? Note: Stäubli recommends using a calibrated torque wrench. The NFPA National Electric Code (NEC 2017) requires a calibrated torque wrench (Section 110.14(D)).

? Note: For component assembly, an ambient temperature between -15°C and 35°C is recommended.

? Note: Do not bottom out the capnut.

Mating and Disconnecting

Without Safety Lock Clip PV-SSH4

• Mating (Illustration 19):

  Mate the cable couplers until a "Click" can be heard. Check correct engagement by lightly pulling (max. 20 N pulling force).

  ❗ Attention: Partially engaged connectors are not permitted as this can lead to permanent clip deformation and loss of locking function. Always verify correct mating.

• Disconnecting (Illustration 20):

  Push the unlocking pins of PV-MS or PV-MS-PLS onto the locking clips (X) of the socket and separate the coupling.

With Safety Lock Clip PV-SSH4

• Mating (Illustration 21):

  Mate the cable couplers until a "Click" can be heard. Check correct engagement by lightly pulling (max. 20 N pulling force).

• Disconnecting:

  Push the unlocking pins of PV-MS or PV-MS-PLS into the openings provided in PV-SSH4 and onto the locking clips of the socket, then separate the coupling.

Notes on Installation

? Note: If the connector is used in low-voltage DC applications other than photovoltaic systems, consult the Stäubli Technical Description Report (Link provided).

General Notes on Installation:

• Protect unmated connectors with sealing caps (socket: 32.0716, plug: 32.0717) from environmental factors (moisture, dirt, dust).
• Do not mate contaminated connectors.
• Avoid contact with chemicals.

Cable Routing and Wire Management:

• Allow a minimum of 20 mm of cable to exit straight from the seal without bending or stress.
• Ensure the connector is not at the lowest point of cabling where water can collect.
• Refer to cable manufacturer's specifications for minimum bending radius.

Diagram: Shows a cable exiting straight for at least 20 mm (✔️ Correct) vs. a sharp bend (❌ Incorrect).

Contaminated/Damaged Connectors:

• Prevent contamination from the environment (soil, water, insects, dust).
• Prevent surface contamination (stickers, paint, heat shrink tubing).
• Do not place the connector directly on the roofing surface.
• Do not allow the connector to be in standing water.
• Do not attach cable ties directly to the connector body.

Mechanical Stress:

• Ensure connectors are not subjected to permanent mechanical tensile load or vibration.
• Connectors shall not be under strain from cable management.

Technical Data

¹⁾ Cables connected to the connector shall be suitable for use in photovoltaic systems and shall comply with the requirements of IEC 62930.

²⁾ IEC DC 1500 V: Only for use in PV-systems in access-restricted areas.

³⁾ For applicable cable diameter, please see Table 3 in this assembly instructions.

⁴⁾ Engineering considerations: Application associated current ratings have to be verified in the products end-use and shall not exceed the maximum operating temperature.

Notes

This section is intentionally left blank in the original document.

Manufacturer Information

Manufacturer: Stäubli Electrical Connectors AG

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