Stäubli Crimping Pliers PV-CZM-...

Operating Instructions

Safety Instructions

Importance of the instruction manual: NOT following the instruction manual and safety instructions could result in life-threatening injuries due to electric shock, electric arcs, fire, or failure of the system.

Follow the entire instruction manual.

Use the product only according to this instruction manual and the technical data. The digital instruction manual and the technical data are available at: www.staubli.com/re-downloads.html

Intended use

The present hand tools are in place to deliver crimp excellence for Stäubli PV connectors with cables. Crimpings shall be carried out only in de-energized state of the cables.

The hand tool is NOT suitable for Live working (IEC 60900).

Crimping pliers emergency opening

Required tool for emergency opening: Screwdriver with fine tip e.g. 3 x 75 mm.

Action step: Turn the screw with the screwdriver (clockwise/counterclockwise).

Result: The locking mechanism loosens.

Note: Once the crimping pliers have been opened using the emergency opening, the metal crimp in process needs to be discarded. No special action is necessary to use the crimping pliers for any next crimp operation following an emergency opening.

Product overview

Crimping pliers with interchangeable crimping dies and locators.

Crimping Pliers

PV-CZM-61100
Conductor cross sections: 2.5 mm², 4 mm², 6 mm²
PV-CZM-60100
Conductor cross sections: 4 mm², 6 mm², 10 mm²

Locators

MC4 connectors: PV-LOC-MC4 (Order No. 32.6081)
MC4-Evo 2 connectors: PV-LOC-MC4-EVO 2 (Order No. 32.6083)
MC4 connectors: PV-LOC-MC4 (Order No. 32.6082)
MC4-Evo 2 connectors: PV-LOC-MC4-EVO 2 (Order No. 32.6084)

Note: Locators with black metal body must be used only for MC4 crimp terminals. Locators with grey metal body must be used only for MC4-Evo 2 crimp terminals.

Crimping Dies

For cable cross sections 4 mm², 6 mm² and 10 mm²
Type: PV-ES-CZM-60100
Order No.: 32.06021-60100
For cable cross sections 2.5 mm², 4 mm² and 6 mm²
Type: PV-ES-CZM-61100
Order No.: 32.6021-61100

Note: The crimping pliers are not designed for use with crimping terminals PV-KST4/5..., PV-KBT4/5..., PV-KST4/8..., PV-KBT4/8..., PV-KBT4/13..., PV-KST4/13.... See table on page 4.

Note: Crimping of 8 AWG (10 mm²) MC4 barrel crimps is not listed in the related connector UL file.

Exchanging the crimping die

Removing the crimping die

Close the crimping pliers and hold it closed.
Unlock the locator (if still mounted); pull it upwards out of the crimping pliers.
Completely unscrew screw S (long) and S1 (short) using an Allen key 2.5 mm (not included).
Open the crimping pliers.
Remove the upper crimping die.
Remove the lower crimping die.

Fitting the crimping die

The crimping dies can be inserted only when the handles are open. Insert the dies separately. The laser identification of the dies needs to face towards the operator as well as the crimping pliers identification.

Note: When inserting the dies, make sure that the anvil (lower die) is inserted first, then the punch.

Close the crimping pliers.
Place the screws in the correct position. Do not damage the screw heads.
Screw in screw S (long) and S1 (short) completely.

Locator assembly

Note: The pictures describe the locator for MC4-Evo 2 crimps. The assembly of the locator for MC4 is comparable.

Affix locator onto the guide pin.
Rotate the locator (held magnetically).
Lock the locator.

Crimping

Open clamp (K) and hold tight.
Insert the contact in the appropriate cross-section range.
Turn the crimping flaps (C) upwards.
Release clamp (K). The contact is locked.
Verify if the crimping flaps are still correctly aligned.
Press the crimping pliers gently together until the crimping flaps are properly located within the crimping die.
Insert the stripped cable end until the cable strands come up against the clamp.
Completely close the crimping pliers.

Note: Observe the stripping length of the PV cable supplier. Do not damage strands when stripping the cable!

After crimping:

Move the locator to default position.
Remove contact (see arrow in illustration for interaction to achieve default position of locator).

Note: The crimp terminals shall not be released from the crimping pliers under force. They should come out easily.

Verify the crimped assembly

Visually inspect the crimped connection according to the criteria described in EN 60352-2.

Good crimp

Confirm that:

All of the strands have been captured in the crimp sleeve.
The crimp sleeve is not deformed or missing any portion of the crimp flaps.
The crimp is symmetrical in shape.
A "brush" of conductor strands are visible on the contact side of crimp.

Crimp Height and Width Specifications

MC4-Evo 2

Conductor cross section mm²	Coding	Conductor cross section AWG	Crimp height ± 0.05 mm	Crimp width ± 0.1 mm	Contact type	Order No.
2.5	A1	14	1.8	3.11	PV-SP4-EVO 2/2,5 PV-BP4-EVO 2/2,5	32.0520 P* 32.0120 P
4	B1	12	2.15	4.20	PV-SP4-EVO 2/6 PV-BP4-EVO 2/6	32.0521 P* 32.0121 P*
6	C1	10	2.4	4.28	PV-SP4-EVO 2/6 PV-BP4-EVO 2/6	32.0521 P* 32.0121 P*

MC4

Conductor cross section mm²	Coding	Conductor cross section AWG	Crimp height ± 0.05 mm	Crimp width ± 0.1 mm	Contact type	Order No.
2.5	A1	14	1.8	3.11	PV-SP4/2,5 PV-BP4/2,5	32.0506 P* 32.0106 P*
4	B1	12	2.15	4.20	PV-SP4/6 PV-BP4/6	32.0507 P* 32.0107 P*
6	C1	10	2.4	4.28	PV-SP4/6 PV-BP4/6	32.0507 P* 32.0107 P*

Bad crimps:

Stamped parts bent wrongly
Material flow outwards
Open crimp wings
Not included strands

Notes

Manufacturer: Stäubli Electrical Connectors AG
Stockbrunnenrain 8
4123 Allschwil/Switzerland
Tel. +41 61 306 5555
Fax +41 61 306 5556
mail ec.ch@staubli.com
www.staubli.com/electrical

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