Product Overview
The MC4-Evo 2 branch connector, model MA292, is designed for electrical connections within DC circuits of a PV system, primarily for the parallel connection of two PV strings.
Components:
- Socket (Buchse): Model PV-AZB4-EVO 2-UR
- Plug (Stecker): Model PV-AZS4-EVO 2-UR
Optional Accessories:
- Socket Sealing Cap (Buchsen-Schutzkappe): Model PV-BVK4
- Plug Sealing Cap (Stecker-Schutzkappe): Model PV-SVK4
Safety Instructions
Failure to follow assembly and safety instructions can lead to life-threatening injuries from electric shock, electric arcs, fire, or system failure.
Importance of Assembly Instructions
- Follow all assembly instructions completely.
- Use and install the product only according to these instructions and technical data.
- Keep instructions for future reference and pass them to subsequent users.
Intended Use
The product electrically connects components within the DC circuits of a PV system. Its primary function is the parallel electrical connection of two PV strings.
Requirements for Personnel
Assembly and installation must be performed exclusively by a qualified electrician or an electrically instructed person.
- Electrician: A person with appropriate professional training, knowledge, and experience to identify and avoid electrical hazards, capable of selecting and using suitable personal protective equipment.
- Electrically Instructed Person: A person instructed or supervised by an electrician to identify and avoid electrical hazards.
Prerequisites for Installation and Assembly
- Never use obviously damaged products.
- Only use tools, materials, and auxiliary means approved by Stäubli.
Safe Assembly and Mounting
Live parts can remain energized even after isolation or disconnection. Install the product only when the PV module is de-energized.
Mating and Disconnecting
- Always de-energize the PV system before mating and disconnecting connectors.
- Never disconnect connectors under load.
- Never connect Stäubli connectors with connectors from other manufacturers.
- Never mate contaminated connectors.
Do Not Modify or Repair Component
- Do not modify components after assembly.
- Replace defective components.
Installation Notes
General Notes
- Unmated connectors must be protected from environmental impact (moisture, dirt, dust, etc.) using sealing caps.
- Connectors must not come into contact with any chemicals.
- Install connectors to minimize exposure to direct sunlight.
Contaminated/Damaged Connectors
- Ensure connectors are not contaminated by environmental influences (e.g., soil, water, insects, dust).
- Do not allow the connector surface to be contaminated (e.g., with stickers, paint, heat shrink tubing).
- Do not place connectors directly on roofing surfaces.
- Avoid placing connectors at the lowest point of cabling where water can collect.
- Do not allow connectors to be in standing water.
- Do not mount cable ties directly on the connector body.
Mechanical Stress
- Connectors should not be strained by cable management.
- Ensure connectors are not subjected to permanent mechanical tensile load or vibration.
- Isolate connectors from dynamic movement and mechanical load, e.g., from moving components of a PV-tracker system.
Note for Transportation and Repacking
Ensure that the locking clips are not subjected to excessive mechanical force.
Thermal Stress
- Ensure connectors are not exposed to excessive thermal stress.
- Install connectors to ensure sufficient heat dissipation.
- Installation in areas that restrict airflow (e.g., large bundles, split cable harnesses, or other housings) is not permitted.
- Direct burial of connectors is not permitted.
Tools and Storage
Tools
- MC4-Evo 2 Assembly and Unlocking Tool: Model PV-MS-PLS/2 (Order No. 32.6058). For operating instructions, see www.staubli.com/re-downloads.html.
- MC4-Evo 2 Unlocking Tool: Model PV-MS-MC4-EVO (Order No. 32.6066).
Storage
- Store components at a constant temperature between -30 °C and +60 °C, with relative humidity below 70%.
- Protect components from direct rainfall, condensation, or similar moisture.
- Keep components away from acids, alkalis, gases, acetone, or other chemically aggressive substances.
Mating and Disconnecting
Mating
- Mate the connectors until an audible "click" is heard.
- Verify correct engagement by gently pulling the connector.
Attention: Assembly of not fully engaged connectors is not permitted as it can lead to permanent deflection of clips and loss of locking function. Always verify correct mating.
Disconnecting
- Push the unlocking pins of the MC4-Evo 2 assembly and unlocking tool onto the locking clips of the socket.
- Separate the connection.
Note: Alternatively, you can use the MC4-Evo 2 unlocking tool.
Example of Parallel Connections
This section illustrates the connection of PV modules in parallel using branch connectors.
Important Considerations:
- When installing PV modules connected in parallel, ensure that the strings are connected correctly.
- When connecting cable-bound connectors to the MC4-Evo 2 branch connector, the rated data (current carrying capacity and rated voltage) of the branch connector depends on the connected cable cross-sections. Refer to Tab. 1 or Tab. 2 on page 7 for details based on the certification area.
- Always observe the assembly instructions of the connectors connected to the MC4-Evo 2 branch connector.
- Installations where a branch connector is directly plugged into a panel receptacle are not allowed.
Product Specifications
Current, voltage ratings, and upper limiting temperature are determined by the corresponding mating connector from Stäubli. Detailed specifications are provided in Tab. 1 and Tab. 2.
Tab. 1 TÜV Rheinland
| Type | MC4 | MC4-Evo 2 |
|---|---|---|
| PV-KST4/xy-UR; PV-KST4/10y PV-KBT4/xy-UR; PV-KBT4/10y | PV-KST4-EVO 2/xy-UR; PV-KST4-EVO 2A/xy PV-KBT4-EVO 2/xy-UR; PV-KBT4-EVO 2A/xy | |
| Rated Voltage IEC | DC 1000 V | DC 1500 V |
| Rated Current IEC | 22 A (2.5 mm²) 39 A (4 mm²) 39 A (6 mm²) 45 A (10.0 mm²) | 39 A (2.5 mm²) 45 A (4 mm²) 53 A (6 mm²) 60 A (10.0 mm²) |
| Upper Limit Temperature (ULT) | 105 °C | 115 °C |
Tab. 2 UL
| Type | MC4 | MC4-Evo 2 |
|---|---|---|
| PV-KST4/xy-UR PV-KBT4/xy-UR | PV-KST4-EVO 2/*-UR; PV-KST4-EVO 2A/* PV-KBT4-EVO 2/*-UR; PV-KBT4-EVO 2A/* | |
| Rated Voltage UL | DC 1500 V | DC 1500 V |
| Rated Current UL | 30 A (AWG14) 35 A (AWG12) 50 A (AWG10) 70 A (AWG8) 95 A (AWG6) | 30 A (AWG14) 35 A (AWG12) 50 A (AWG10) 70 A (AWG8) |
| Max. Operating Temperature (MOT) | 90 °C | 90 °C |
Technical Data
| Type Designation | PV-AZB4-EVO 2-UR / PV-AZS4-EVO 2-UR |
|---|---|
| Rated voltage | DC 1500 V |
| Test voltage | 8 kV 3) |
| Rated current (IEC) | 60 A 1) |
| Rated current (UL) | 95 A 2) |
| Rated impulse voltage | 16 kV |
| Ambient temperature range (IEC) | -40 °C...+85 °C |
| Ambient temperature range (UL) | -40 °C...+90 °C |
| Transportation/storage temperature range | -30 °C...+60 °C |
| MOT max. operating temperature (UL) | +90 °C |
| Transportation/storage relative humidity | < 70% |
| Upper limiting temperature | 115 °C 1) |
| Degree of protection, mated | IP65/IP68 (1 m, 168 h) 5) |
| Degree of protection, unmated | IP2X |
| Overvoltage category | III |
| Contact resistance of plug connectors | < 0.5 mΩ |
| Locking system | Locking type |
| Safety class | II |
| Contact system | MULTILAM |
| Number of mating cycles | 100 |
| Contact material | Copper, tin plated |
| Insulation material | PA |
| Flame class | UL94-V0 |
| TÜV Rheinland certified according to IEC 62852:2014/AMD1:2020 | R 60149724 |
| UL certified according to UL6703 and CSA C22.2 No. 182.5 (cULus Listed and UL Recognized) 4) | E343181 |
| Compatible with connector type | Original MC4 cable connectors Original MC4-Evo 2 cable connectors |
| Max. operating altitude above sea level | 5000 m; AK 60159400 |
| Temperature Level according to IEC TS 63126 | Level 2; AK 60158914 |
| CE | CE declaration of conformity |
Notes on Technical Data:
1) Current and voltage ratings, as well as upper limiting temperature, are limited by the corresponding mating connector from Stäubli. Refer to Tab. 1, page 7 for details.
2) Current and voltage ratings, as well as upper limiting temperature, are limited by the corresponding mating connector from Stäubli. Refer to Tab. 2, page 7 for details.
Engineering Considerations: Application associated current ratings must be verified in the product's end-use and shall not exceed the maximum operating temperature of the MC4 Evo 2 branch connector.
3) Rated voltage 1000 V and test voltage 6 kV with mated MC4 connector; 1500 V and test voltage 8 kV with mated MC4-Evo 2 connector.
4) The PV connectors are also certified as cULus Listed products, even if the UL Recognized Component Mark (UR) is molded on the PV connector housing.
5) The ingress protection (IP) of a connection is determined by the component with the lower ingress protection.
Manufacturer Information
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
