Stäubli MC4-Evo 2 Connector MA298 Assembly Instructions
Valid for: PV-KBT4-EVO 2A/... PV-KST4-EVO 2A/...
Safety Instructions
Importance of the Assembly Instructions
Failure to follow safety and assembly instructions can lead to life-threatening injuries from electric shock, electric arcs, fire, or system failure. Always adhere strictly to all instructions and use the product only as specified.
Intended Use
The connector electrically connects components within the DC circuits of a PV array. It may also be used in other low-voltage DC systems. For alternative uses, consult Stäubli for specific requirements.
Requirements for Personnel
Assembly, installation, and commissioning must be performed by a qualified electrician or an electrically instructed person.
Prerequisites for Installation and Assembly
- Never use a damaged product.
- Only use tools and materials approved by Stäubli.
- Only assemble approved PV cables to the connector.
Safe Assembly and Mounting
Live parts can remain energized even after isolation. Install the product only when the PV module is de-energized.
Mating and Disconnecting
- Always de-energize the PV system before mating or disconnecting connectors.
- Never disconnect connectors under load.
- Never connect Stäubli connectors with connectors from other manufacturers.
- Never mate contaminated connectors.
- A tool is required to open the locking-type connector.
Do NOT Modify or Repair Component
- Mount connectors only once.
- Do not modify connectors after assembly.
- Replace defective connectors.
Notes on Installation
General Notes
- Unmated connectors must be protected from environmental impact (moisture, dirt, dust) using sealing caps.
- Do not mate contaminated connectors.
- Connectors must not come into contact with chemicals.
Cable Routing and Wire Management
Cable management must allow a minimum of 20 mm of cable exiting the seal without bending or stress. Ensure the connector is not positioned at the lowest point of cabling where water can collect. Refer to cable manufacturer specifications for minimum bending radius.
[Diagram: Cable exit length illustration showing minimum 20mm clearance.]
Contaminated/Damaged Connectors
- Prevent environmental contamination (soil, water, insects, dust).
- Prevent surface contamination (stickers, paint, heat shrink tubing).
- Do not allow the connector to be directly on the roofing surface.
- Avoid installation in standing water.
- Do not mount cable ties directly on the connector body.
Mechanical Stress
Ensure connectors are not subjected to permanent mechanical tensile load or vibration. Connectors must not be strained by cables and should be constrained from dynamic movement, isolated from mechanical load (e.g., from moving components of a PV-Tracker system).
Thermal Stress
Ensure the connector is not exposed to excessive thermal stress. Install for sufficient heat dissipation. Installation is not permitted in areas that restrict airflow (e.g., large bundles, split cable harnesses, other housings). Direct burial is not permitted.
Tools
The following tools are recommended for assembly:
| Illustration | Tool Name | Description | Order No. | Notes |
|---|---|---|---|---|
| [Illustration of stripping pliers] | Stripping Pliers PV-AZM... | For conductor cross sections 1.5-2.5/4/6 mm² (14/12/10 AWG) and 4/6/10 mm² (12/10/8 AWG) | PV-AZM-156 / PV-AZM-410 | Operating instructions MA267 available at www.staubli.com/re-downloads.html |
| [Illustration of crimping pliers] | Crimping Pliers PV-CZM... with Locator | For crimping range 2.5/4/6 mm² (14/12/10 AWG) and 4/10/6 mm² (12/8/10 AWG) | PV-CZM-61100 / PV-CZM-60100 with PV-LOC-MC4-EVO 2 (32.6084 / 32.6083) | Operating instructions MA704 available at www.staubli.com/re-downloads.html |
| [Illustration of assembly/unlocking tool] | Assembly and Unlocking Tool | PV-MS-PLS or PV-MS | 32.6058 (PV-MS-PLS) / 32.6024 (PV-MS set) | Operating instructions MA270 available at www.staubli.com/re-downloads.html |
| [Illustration of torque tool set] | Torque Tool Set | PV-WZ-TORQUE-SET / Torque wrench 17 mm | 32.0065 | For precise tightening. |
| [Illustration of test plug] | Test Plug | PV-EVO-PST | 32.6073 | For assembly checks. |
| [Illustration of cable cutter] | Cable Cutter | PV-WZ-KS | 32.6080 | For cutting cables. |
Storage
Store components at a constant temperature between -30 °C and +60 °C with relative humidity below 70%. Avoid exposure to moisture and contact with aggressive chemicals.
Cable Preparation
Use cables with class 5 and 6 strands, exclusively tinned copper cables. Do not use oxidized or bare conductors. Stäubli prohibits the use of PVC cables and non-tinned H07RN-F cables for safety reasons.
[Diagram: Cable preparation showing correct stripping length.]
Guideline for Connector Configuration
Note: If the chosen cable diameter falls between two limits, use the smaller sealing. Seals are color-coded: Maroon (DI), Yellow (DX), Grey (DII).
Connector Configuration Tables
Table 1: TÜV Rheinland Certification
| Conductor Cross Section (mm²) | AWG | Outer Cable Diameter A (mm) | Reference Dimension b (mm) | Usable Seals | PV Cable Type (TÜV / TÜV+UL) |
|---|---|---|---|---|---|
| 1.5 - 2.5 | 14 | ~ 4.0 | 4.7 - 6.4 | DI (Maroon) | PV-K...T4-EVO 2A/2.5I / PV-K...T4-EVO 2A/2.5X |
| 4 - 6 | 12/10 | ~ 5.8 | 5.9 - 7.3 | DX (Yellow) | PV-K...T4-EVO 2A/6I / PV-K...T4-EVO 2A/6X |
| 10 | 8 | ~ 6.5 | 6.4 - 8.4 | DII (Grey) | PV-K...T4-EVO 2A/10I / PV-K...T4-EVO 2A/10X |
Table 2: UL Certification
| Cable Type | Conductor Cross Section (mm²) | AWG (Stranding) | Outer Cable Diameter A (mm) | Reference Dimension b (mm) | Usable Seals | PV Cable Type (UL) |
|---|---|---|---|---|---|---|
| TYLZ (USE-2) up to DC 600 V | 2.5 | 14 (19-49) | 4.93 - 6.5 | 5.58 - 6.5 | DI (Maroon) | PV-K...T4-EVO 2A/2.5II |
| ZKLA (PV-wire) up to DC 1000 V | 4 | 12 (19-65) | 5.76 - 7.45 | 6.5 - 8.5 | DX (Yellow) | PV-K...T4-EVO 2A/6II |
| ZKLA (PV-wire) up to DC 2000 V | 6 | 10 (19-105) | 6.5 - 8.5 | 6.5 - 8.5 | DII (Grey) | PV-K...T4-EVO 2A/10II |
| 10 | 8 (19-168) |
Attention: Do not assemble with single jacket cross-linked polyethylene (XLPE) cable, as it does not meet UL 6703 strain relief requirements.
Note for Canada: Installation must comply with CSA C22.1-2021. Use conductors rated for 75°C or higher. Suitable only for Class B and C stranded copper conductors (NFPA NEC 70).
Crimping Procedure
Stripping the Cable (ill. 8): Strip cable insulation 6.0 mm to 7.5 mm. Do not cut individual strands.
Crimping (ill. 9, 10, 11):
- Open clamp (K) and insert contact into the appropriate section. Turn crimping flaps upwards. Release clamp (K) to lock the contact.
- Ensure the contact is correctly seated and held by the clamp.
- Verify crimping flaps are aligned. Gently press pliers until flaps are properly located in the crimping die.
- Insert stripped lead end until strands touch the locator.
- Completely close the crimping pliers, then open them and remove the crimped cable assembly.
[Diagrams illustrating stripping and crimping steps.]
Assembly Check
Visual Crimp Check (ill. 12): Confirm all strands are captured, the crimp sleeve is not deformed, and the crimp is symmetrical with a visible 'brush' of conductor strands.
Contact Engagement (ill. 13): Insert crimped contact into the insulator until it clicks. Gently pull the cable to verify correct engagement.
Test Pin Check (ill. 14): Insert the test pin. If assembly is correct, the white mark on the test pin should remain visible.
Cable Gland Tightening (ill. 15): Pre-tighten the cable gland using PV-MS-PLS, then tighten with the torque set (PV-WZ-TORQUE-SET), supporting the insulator with PV-MS-PLS.
| Conductor Cross Section (mm²) | AWG | Tightening Torque (Nm) |
|---|---|---|
| 2.5 | 14 | 4.5 |
| 4.0 | 12 | 4.0 |
| 6.0 | 10 | 3.5 |
| 10.0 | 8 | 4.0 |
Notes: Recommended ambient temperature for assembly is -15 °C to 35 °C. Torque values should be adapted to specific PV cables. Stäubli recommends using a calibrated torque wrench, as required by NFPA NEC 2017.
Mating and Disconnecting
Mating (ill. 16): Connect the connectors until a 'click' is heard. Verify engagement by lightly pulling (max 20 N). Attention: Do not fully engage connectors, as this can permanently damage the locking clips. Always verify correct assembly.
Disconnecting (ill. 17): Use PV-MS-PLS/2 or PV-MS to disconnect.
Note: Protect unmated connectors from contamination with Stäubli sealing caps. Warning: Do not bottom out the capnut.
Technical Data
| Parameter | Specification |
|---|---|
| Type Designation | PV-KST4-EVO 2A/xy; PV-KBT4-EVO 2A/xy |
| Connector System | Ø 4 mm |
| Rated Voltage (IEC) | CC 1500 V |
| Rated Voltage (UL) | CC 1500 V |
| Rated Current (IEC) | 39 A (2.5 mm²), 45 A (4.0 mm²), 53 A (6.0 mm²), 69 A (10.0 mm²) |
| Rated Current (UL) | 30 A (14 AWG), 39 A (12 AWG), 50 A (10 AWG), 70 A (8 AWG) |
| Rated Impulse Voltage | 16 kV |
| Ambient Temperature Range | -40 °C to +85 °C |
| Transportation/Storage Temperature Range | -30 °C to +60 °C |
| Transportation/Storage Relative Humidity | < 70% |
| Upper Limiting Temperature | 115 °C (IEC) |
| Degree of Protection, Mated | IP65/IP68 (1 m, 168 h) |
| Degree of Protection, Unmated | IP2X |
| Overvoltage Category | III |
| Contact Resistance of Plug Connectors | < 0.2 mΩ |
| Locking System | Locking Type |
| Safety Class (IEC) | II |
| Contact System | MULTILAM |
| Type of Termination | Crimping |
| Number of Mating Cycles | 100 |
| Contact Material | Copper, tin plated |
| Insulation Material | PA |
| Flame Class | UL94-V0 |
| Ammonia Resistance | Certified (TÜV Rheinland acc. to 2 PfG 1911/04.2016) |
| TÜV Rheinland Certification | Acc. to IEC 62852:2014+Amd.1:2020 |
| UL/CSA Certification | Certified acc. to UL6703 and CSA C22.2 No. 182.5 (cULus Listed and UL Recognized) |
| JET Certification | 1625-C4304-336 |
| Max. Altitude for Operation | 5000 m |
| Temperature Level (IEC TS 63126) | Level 2 |
Notes on Certifications:
- Connectors evaluated with ZKLA (PV-wire) or TYLZ (USE-2) cable types. Refer to Table 2 for cross-sections.
- Connector compliance with UL6703 requires assembly as specified in these instructions.
- PV connectors are certified cULus Listed, even if the UL Recognized Component Mark (UR) is molded on the housing.
Notes
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.
