MC4-Evo Ready Connector MA293 (en) Assembly Instructions
Valid for: PV-KST4-EVO READY, PV-KBT4-EVO READY
Safety Instructions
Importance of the assembly instructions
⚠️ NOT following the assembly and safety instructions could result in life-threatening injuries due to electric shock, electric arcs, fire, or failure of the system.
- Follow the entire assembly instructions.
- Use and install the product only according to this assembly instructions and the technical data.
- Safely store the assembly instructions and pass them on to subsequent users.
Intended use
The connector electrically connects components within the DC circuits of a PV array.
Requirements for personnel
Only an electrician or electrically instructed person may assemble, install, and commission the system.
- An electrician is a person with appropriate professional training, knowledge, and experience to identify and avoid the dangers that may originate from electricity. An electrician is able to choose and use suitable personal protective equipment.
- An electrically instructed person is a person who is instructed or supervised by an electrician and can identify and avoid the dangers that may originate from electricity.
Prerequisites for installation and assembly
- NEVER use an obviously damaged product.
- ONLY tools, materials and auxiliary means approved by Stäubli shall be used.
- ONLY approved PV cables shall be assembled to the connector.
Safe assembly and mounting
Live parts can remain energized after isolation or disconnection. ⚠️ ONLY install the product when the PV module is de-energized.
Mating and disconnecting
- ALWAYS de-energize the PV system before mating and disconnecting the connectors.
- NEVER disconnect the connectors under load.
- NEVER connect male or female part of Stäubli connector with connectors of other manufacturers.
- NEVER mate contaminated connectors.
Do NOT modify or repair component
- Mount connector only once.
- Do NOT modify connectors after assembly.
- Replace defective connectors.
Tools required
(ill. 1) Stripping pliers PV-AZM...
| Conductor cross section [mm²] | AWG | Type | Order No. |
|---|---|---|---|
| 1.5/2.5/4/6 | PV-AZM-156 | 32.6027-156 | |
| 4/6/10 | PV-AZM-410 | 32.6027-410 |
ℹ️ Note: Operating instructions MA267 available at www.staubli.com/re-downloads.html
(ill. 2) Unlocking tool for MC4-Evo 2
PV-MS-MC4-EVO 2. Order No.: 32.6066
(ill. 3) Recommended tooling: Open-end spanner set for MC4-Evo ready
MC4-MS-EVO READY. Order No.: 32.6070
Cable preparation
Cables with an outer diameter of 5.4 mm to 7.6 mm and nominal conductor cross-sections of 4 mm² and 6 mm² can be used.
Cables connected to the connector shall be suitable for use in photovoltaic systems and shall comply with the requirements of IEC 62930. The flexible conductors shall be class 5 or class 6 according to IEC 60228.
⚠️ Attention: Use tinned copper conductors. Do not use uncoated (bare) nor already oxidized conductors. All Stäubli PV cables have high-quality, tinned conductors. For safety reasons, Stäubli prohibits the use of PVC cables and the use of non-tinned cables of type H07RN-F.
(ill. 4) Stripping the cable
Use the stripping pliers and remove the cable insulation by 15 mm up until 16.5 mm.
⚠️ Attention: Do not damage nor cut any strands when stripping the cable.
ℹ️ Note: The length can be checked using the assembly key (according to the figure on the left, ill. 5).
(ill. 6) Twisting strands
Use 2 fingers and gently twist the strands, compressing them into one twisted shape.
⚠️ Attention: Misaligned or missing strands could lead to an increased contact resistance.
Connector assembly
(ill. 7) Cable insertion and locking
Insert the cable straight into the connector. The cable latches engage with an audible [click sound].
(ill. 8) Confirm the latch mechanism
Gently pull the cable. The cable should not protrude the connector when slightly pulling.
Fastening the connectors
(ill. 9) Tightening the nut
Bottom out the nut for this product with a torque of approximately 3 – 4 [Newton-meters].
ℹ️ Note: It is feasible to screw the connector manually. However, it is recommended to use the set of assembly tools (see ill. 3) to carry out this manufacturing step.
(ill. 10) Attention to IP protection
⚠️ Attention: The [IP rating] when plugged in is only guaranteed if the connector has been assembled correctly!
Mating and disconnecting the cable coupler
(ill. 11 + ill. 12) Mating
Plug the line connectors together until they latch into place.
⚠️ Attention: Assembly of not fully engaged connectors is not permitted as this could lead to a permanent deflection of clips and thus to a potential loss of the locking function. The correct mating has to be verified.
Check that the connectors are correctly engaged by slightly pulling on the connectors.
ℹ️ Note: Unmated connectors must be protected from any contamination using Stäubli sealing caps.
(ill. 13 + ill. 14) Disconnecting
Push the unlocking tool onto the clips.
Disconnect the previously mated connectors.
Notes on installation
General notes on installation
- Unmated connectors must be protected from environmental impact (moisture, dirt, dust, etc.) with sealing caps.
- Do not mate contaminated connectors.
- Connectors must not come into contact with any chemicals.
Cable routing and wire management
Cable management must allow a minimum of 20 mm of cable that exits directly from the cable seal without bending or stress. Refer to cable manufacturers specification for minimum bending radius.
Diagram: Too much bend of cable close to connector
Illustrates excessive bending of the cable near the connector, showing a sharp angle.
Diagram: Proper cable routing
Illustrates correct cable routing, showing a gentle curve away from the connector with at least 20 mm straight section.
Contaminated/damaged connectors
- Do not allow connectors to be contaminated by the environment (e.g. soil, water, insects, dust).
- Do not allow the connector to be contaminated on its surface (e.g. stickers, paint, heat shrink tubing).
- Do not allow that the connector is directly on the roofing surface.
- Do not allow the connector to be located at the lowest point of the wiring loom to avoid water accumulation at the connector.
- Do not allow that the connector is in standing water.
- Do not allow cable ties to be mounted directly on the connector body.
Mechanical stress
- Check that the connectors are not subjected to a permanent mechanical tensile load or vibration.
- Connectors shall not be under strain from cable management.
Technical Data
| Parameter | Value |
|---|---|
| Type designation | PV-KST4-EVO READY, PV-KBT4-EVO READY |
| Connector system | Ø 4 mm |
| Rated voltage | DC 1500 V (IEC 62852:2014+Amd.1:2020) |
| Rated current | 30 A |
| Rated impulse voltage | DC 16 kV (1500 V) |
| Ambient temperature range | -40 °C ... +85 °C (IEC) |
| Transportation/storage temperature range | -30 °C ... +60 °C |
| Transportation/storage relative humidity | < 70% |
| Upper limiting temperature | 115 °C (IEC) |
| Degree of protection, mated | IP65/IP68 (1 m, 1 h) |
| Degree of protection, unmated | IP2X |
| Overvoltage category | III |
| Contact resistance of plug connectors | < 0.5 mΩ |
| Polarity of connectors | Socket = +/positive; Plug = -/negative |
| Locking system | Locking-type |
| Class (IEC) | II |
| Type of termination | Spring clamp (tool free connection) |
| Safety instruction | Do not disconnect under load |
| Contact material | Copper, tin plated |
| Insulation material | PA |
| TÜV Rheinland certified | According IEC 62852:2014+Amd.1:2020 |
| Mateable with connector type | MC4 (Tested exclusively in connection with connectors from the MC4 product family.) |
1) The connectors are to be used with cables according to the following table:
(Tab. 1) Allowed cable type
| Description | Wire cross-section [mm²] | Outer diameter [mm] |
|---|---|---|
| PV cable according IEC 62930:2017 or EN 50618:2014 | 4.0/6.0 | 5.4 – 7.6 |
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
