Stäubli MC4-Evo Ready Connector MA293

Content Overview

• Safety Instructions
• Tools Required
• Recommended Tooling
• Cable Preparation
• Connector Assembly
• Fastening the Connectors
• Mating and Disconnecting the Cable Coupler
• Notes on Installation
• Technical Data

Product Images:

• Female cable coupler, model PV-KBT4-EVO READY, order number 32.0030.
• Male cable coupler, model PV-KST4-EVO READY, order number 32.0029.
• Optional accessory: Sealing cap for female cable coupler, model PV-BVK4, order number 32.0716.
• Optional accessory: Sealing cap for male cable coupler, model PV-SVK4, order number 32.0717.

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

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 these 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 parts of Stäubli connectors 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

Illustration: Stäubli PV-AZM stripping pliers.

Note: Operating instructions MA267 available at www.staubli.com/re-downloads.html

Illustration: Stäubli unlocking tool for MC4-Evo 2, model PV-MS-MC4-EVO 2, order number 32.6066.

Recommended Tooling

Illustration: Stäubli open-end spanner set for MC4-Evo ready, model MC4-MS-EVO READY, order number 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 comply with IEC 62930. 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 non-tinned cables of type H07RN-F.

Action: Use the stripping pliers and remove the cable insulation by 15 mm up to 16.5 mm.

Attention: Do not damage or cut any strands when stripping the cable.

Note: The length can be checked using the assembly key (refer to illustration).

Action: Use 2 fingers and gently twist the strands to compress them into one twisted shape.

Attention: Misaligned or missing strands could lead to an increased contact resistance.

Connector Assembly

Cable Insertion and Locking

Action: Insert the cable straight into the connector. The cable latches with an audible "click".

Confirm the Latch Mechanism

Action: Gently pull the cable. The cable should not protrude the connector when slightly pulling.

Fastening the Connectors

Action: Bottom out the nut for this product with a torque of approximately 3 – 4 Nm.

Note: It is feasible to screw the connector manually. However, it is recommended to use the set of assembly tools (see recommended tooling section) to carry out this manufacturing step.

Attention: The IP (ingress protection) class is only guaranteed if the connector has been assembled correctly!

Mating and Disconnecting the Cable Coupler

Mating

Action: 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 must be verified.

Action: Check that the connectors are correctly engaged by slightly pulling on them.

Note: Unmated connectors must be protected from any contamination using Stäubli sealing caps.

Disconnecting

Action: Push the unlocking tool onto the clips.

Action: 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' specifications for minimum bending radius.

Illustration: Diagram showing minimum 20 mm cable exit from the seal and proper cable routing, avoiding sharp bends.

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 the connector to be 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.
• Do not allow the connector to be 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 permanent mechanical tensile load or vibration.
• Connectors shall not be under strain from cable management.

Technical Data

Allowed Cable Types