Stäubli TwinBox Connector Set Assembly Guide

Product Information

This assembly guide is valid for:

MC4 and MC4-Evo are registered trademarks owned by Stäubli.

Safety Instructions

Importance of the Assembly Guide

Failure to follow this assembly guide and the following safety instructions can result in danger of electric shock, arcing, fire, or system failure.

• Follow the assembly guide completely.
• Assemble, connect, and use the connector only as per this assembly guide and the technical data.
• Keep the assembly guide and pass it on to subsequent users.

Intended Use

The connector set electrically connects the PV module to other components in the DC circuits of a PV system.

Personnel Requirements

Assembly and installation must be performed exclusively by a qualified electrician or a trained person.

• A qualified electrician is a person with suitable training, knowledge, and experience to recognize and avoid hazards arising from electricity. They are capable of selecting and using appropriate protective equipment.
• A trained person is instructed or supervised by a qualified electrician to recognize and avoid hazards arising from electricity.

Prerequisites for Installation and Assembly

• NEVER use obviously damaged connectors.
• ONLY use Stäubli-approved tools, materials, and aids.

Safe Assembly and Installation

Active parts can remain live even after the PV system is de-energized and connectors are disconnected.

• Assemble the connector ONLY when the PV module is de-energized.

Connecting and Disconnecting

• ALWAYS de-energize the PV system before disconnecting and connecting connectors.
• NEVER disconnect the connector under load.
• NEVER connect a Stäubli connector plug or socket with a connector from another manufacturer.
• NEVER connect dirty connectors.

DO NOT Modify or Repair Connector

• Assemble the connector only once.
• DO NOT modify the connector after assembly.
• Replace defective connectors.

Warning Notices and Symbols

[DANGER]: Indicates an imminent hazard situation which, if not avoided, will result in death or severe injury.

[WARNING]: Indicates a potential hazard situation which, if not avoided, could result in death or severe injury.

[CAUTION]: Indicates a potential hazard situation which, if not avoided, may result in minor or moderate injury.

[NOTICE]: Provides additional information that may prevent product damage.

The "Refer to assembly instructions" symbol [i] points to further assembly guides.

1. Product Overview

The TwinBox Connector Set includes:

• Lid
• Socket Connector
• Plug Connector

Required Materials and Tools

Materials

[NOTICE]: The listed materials have been certified for sealing. Using other materials requires separate validation. Please refer to the manufacturer's instructions for materials not included in the delivery scope.

Tools

• Cartridge gun
• Double cartridge gun
• Metal cutting tool
• Lint-free work gloves
• Lint-free cleaning wipes

Optional Accessories

2. Storage

Store components at a constant temperature between -35°C and +60°C, and with relative humidity below 70%.

Do not expose components to direct rain or condensation.

Do not expose components to acids, alkalis, gases, acetone, or other chemically aggressive substances.

3. Assembly of the TwinBox Connector Sets

Preparing the Adhesive Bond

Clean, dry, and degreased bonding surfaces are essential for a durable adhesive bond between the connector and the PV module.

Preparation Steps:

1. Wet a cleaning cloth with cleaning agent.
2. Clean the flat undersides of the connectors with the moistened cloth.
3. Allow the flat undersides of the connectors to dry.
4. Clean the bonding surface of the PV module.
5. Allow the bonding surface of the PV module to dry.
6. Treat the flat undersides of the connectors with a thin layer of primer.
7. Allow the primer to dry.

[NOTICE]: Wipe off any excess primer (e.g., white, chalky substance).

[NOTICE]: Refer to the primer manufacturer's instructions for drying time.

Apply adhesive tape to the flat undersides of the connectors. [NOTICE]: Do not peel off the tape backing yet. [NOTICE]: Follow the adhesive and sealant manufacturer's instructions for surface preparation.

Preparing the Electrical Connection

The TwinBox Connector Set electrically connects the PV module to other components in PV system DC circuits. This may involve soldering or welding work on the PV module.

[NOTICE]: High temperatures during soldering or welding can damage the insulation material.

[NOTICE]: Contact bands with a width of 5 mm are compatible with the TwinBox Connector Set.

The PV module contact bands and the connector contacts must align precisely when making the electrical connection. Ensure the contact bands are clean, dry, and degreased for a proper connection.

Steps:

1. Shorten the PV module contact band to a length of 12 mm.
2. Align the PV module contact band precisely with the connector contact to optimally prepare the electrical connection.

Manufacturing the Adhesive Bond

The connector and the PV module form a durable connection that protects the electrical connection from moisture and contaminants. A sealed adhesive bond is required.

Material: DOWSIL™ 7091 Adhesive/Sealant. Tool: Cartridge gun, lint-free work gloves.

[NOTICE]: Follow the adhesive and sealant manufacturer's processing instructions.

[NOTICE]: Due to the rapid drying time of the adhesive/sealant, these steps must be completed within five minutes.

When applying the adhesive/sealant, observe the following:

• The application must have NO interruptions or air inclusions.
• The application must be uniform and 3 mm thick.
• The application must NOT come into contact with the contact bands.

1. Peel off the adhesive tape backing.
2. Apply the adhesive/sealant in a bead onto the flat underside of the plug connector.
3. Apply the adhesive/sealant in a bead onto the flat underside of the socket connector.
4. Immediately attach the connectors perpendicularly onto the prepared surface of the PV module before the adhesive/sealant forms a skin.

[NOTICE]: The adhesive/sealant begins to skin over in approximately 10-15 minutes (at room temperature and 50% relative humidity).

[NOTICE]: Refer to the PV module manufacturer's instructions for connector placement and electrical connection to the PV module.

5. Allow the adhesive/sealant to cure.

[NOTICE]: Refer to the adhesive/sealant manufacturer's instructions for the curing phase duration in your working environment.

Potting the Electrical Connection

The electrical connection must be potted to protect it from moisture and contaminants.

Material: DOWSIL™ 3-4207 Dielectric Tough Gel Kit. Tool: Double cartridge gun, lint-free work gloves.

Prerequisite: The connector has been bonded and electrically contacted to the PV module.

1. Pour the potting compound flush to the edges of the connector's electrical connection.

[NOTICE]: The overflow chambers catch excess potting compound that occurs when fitting the lid.

Diagram Description: A cross-section view shows the potted interior space and surrounding overflow chambers.

2. Immediately fit the connector lid.

[NOTICE]: The potting compound cures rapidly and can make fitting the lid difficult or impossible.

3. Allow the potting compound to cure.

[NOTICE]: Refer to the potting compound manufacturer's instructions for the curing phase duration in your working environment.

Connecting the PV Module to the PV System Cable Harness

After the PV module's functional check, the MC4 connector system can be connected to the connectors.

[DANGER] Risk of Electric Shock! PV systems operate at dangerous voltages which can cause electric shock upon contact. De-energize the PV system before connecting and disconnecting connectors.

[NOTICE]: Attach protective caps to the connector inputs if you are not connecting connectors immediately after the functional check.

Attaching Protective Caps

[NOTICE]: Refer to the cable manufacturer's instructions.

• Route the cable from the connector at least 20 mm straight from the cable gland without bending.
• Route the cable downwards from the connector so that no moisture can accumulate at the cable gland.
• Route the cable strain-free to avoid mechanical stress on the connection.

4. IP Protection of the TwinBox Connector Sets

Attaching Protective Caps

Attaching protective caps to the connectors is necessary when connectors are not immediately used after the PV module's functional check. The protective caps prevent the ingress of dust, dirt, and moisture into the connector. The ingress of dust, dirt, and moisture impairs the connector's function.

1. Fully push the plug protective cap onto the plug connector.
2. Fully push the socket protective cap onto the socket connector.

5. Technical Data

[NOTICE]: The rated voltage of the overall configuration depends on the lowest-rated component. This must be checked in the certificates.

6. Imprint

Manufacturer

Stäubli Electrical Connectors AG
Stockbrunnenrain 8
4123 Allschwil/Switzerland

Tel: +41 61 306 55 55
Fax: +41 61 306 55 56
E-Mail: ec.ch@staubli.com

Website: www.staubli.com/electrical