Stäubli MC4 Connector MA231 Assembly Instructions

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. The connector can be used for purposes other than those in a PV system, e.g., as a LVDC component. If the component is used for other purposes, then the requirements and specifications may be different from the ones described in this document.

ℹ️ For more information, contact Stäubli: www.staubli.com/electrical

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.
• Use of tool is required to open 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

ℹ️ The local/national installation instructions regarding cables have to be observed.

ℹ️ If the connector is to be used in low-voltage DC applications other than those in a photovoltaic array, please consult the information as provided in the Stäubli Technical Description Report. Link

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.
• Connectors should be installed so that the exposure to direct sunlight is minimized.

Cable routing and wire management

• Cable management must allow a minimum of 20 mm (0.75 inches) of cable that exits directly from the cable seal without bending or stress.
• Do not allow that the connector is at the lowest point of cabling where water can collect.

ℹ️ Refer to cable manufacturers specification for minimum bending radius.

Diagram showing < 20 mm and > 20 mm cable exit.

Contaminated/damaged connectors

• Make sure that the connector or plug connector does not become contaminated due to environmental influences (e.g. natural substances such as 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 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.
• Connectors shall be constrained from dynamic movement and isolated from mechanical load, e.g. from moving components of a PV-Tracker system.

Thermal stress

• Ensure that the connector is not exposed to excessive thermal stress.
• Install the connector in such a way that sufficient heat dissipation is ensured.
• Installation in areas that restrict the air flow (e.g. in large bundles, in split looms or other housings) is not permitted.
• Direct burial of the connector is not permitted.

Tools

Stripping pliers PV-AZM...

ℹ️ Operating instructions MA267: www.staubli.com/re-downloads.html

Assembly and unlocking tool

PV-MS-PLS, Order No. 32.6058 or Open-end spanner set PV-MS, Order No. 32.6024

ℹ️ Operating instructions MA270: www.staubli.com/re-downloads.html

Crimping pliers PV-CZM-6x100

Includes locator and crimping die.

ℹ️ Operating instructions MA704: www.staubli.com/re-downloads.html

Crimping pliers PV-CZM-2x100

Includes locator and crimping die.

ℹ️ Operating instructions MA251: www.staubli.com/re-downloads.html

Assign crimping pliers and locator

Table 1

For open barrel crimps, refer to operating instructions MA704. For the blue crimping pliers set, consult user instruction MA251.

Tools:

• Torque tool set PV-WZ-TORQUE-SET, Order No. 32.0065
• Test plug PV-PST, Order No. 32.6028
• Cable cutter PV-WZ-KS, Order No. 32.6080

ℹ️ Operating instructions MA705: www.staubli.com/re-downloads.html

Storage

• Store the components at a constant storage temperature in the range of -30 °C to +60 °C and at less than 70% relative humidity.
• The components must not be exposed to moisture due to direct rainfall, condensation or similar.
• Do not allow components to come into contact with acids, alkalis, gases, acetone or other chemically aggressive substances.

Guideline for connector configuration

ℹ️ If the outer diameter of the selected cable fits in the range of two different sealing sizes, please select the smaller size.

Cable preparation

For IEC applications cables with flexible conductors of class 5 or 6 according to IEC 60228 shall be connected. For the UL approved range applications power cables of class B or higher shall be connected.

It is recommended to use tinned copper conductors. Do not use uncoated (bare*) nor already oxidized copper conductors. All Stäubli solar 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.

* For bare copper conductors, class B or higher, select the following products: PV-KBT4/5...-UR, PV-KST4/5...- UR, PV-KBT4/8II-UR and PV-KST4/8II-UR.

Diagram showing cable dimensions A and b.

In case that other diameters than those mentioned in Tab. 2 and Tab. 3 are used contact Stäubli.

Choose connector configuration verified by TÜV-Rheinland

Cables connected to the connector shall be suitable for use in photovoltaic systems and shall comply with the requirements of IEC 62930.

Table 2

The sheath material of the PV cable has to meet insulation class 1 according to IEC 60664-1.

Table 3 (UL Configurations)

* preferred conductor stranding: 19-65

If your chosen cable is suitable for both configurations listed in Tab. 2 and 3 as well as in the technical data on page 13, it can be used as a double certified cable according TÜV Rheinland and UL.

For Canada: Installation shall be in accordance with CSA C22.1-2021, Canadian Electric Code, Part I, Edition 25, Revision Date 03/2021, Safety Standard for Electrical Installations. The connectors/devices are intended to be wired with conductors where the ampacity is based on a conductor temperature of 75°C or higher. The connector is suitable for use only with Class B and C stranded copper conductors (See NFPA NEC 70, Chapter 9, Table 10, Edition 2023).

Cable preparation

Stripping the cable

Strip cable insulation (length L) according to ranges mentioned in Tab. 4 and check.

Do not cut strands when stripping the cable.

Table 4: Cable Stripping Lengths "L"

Crimping

For crimping open crimp contacts (B-Crimp)

PV-KxT4/2.5...-UR; PV-KxT4/6...-UR or PV-KxT4/10...

• Open clamp (K) and hold tight.
• Insert the contact in the appropriate cross-section range so that it is completely in the positioning device.
• Turn the crimping flaps (C) upwards so that they look like an "U".
• Release clamp (K). The contact is locked.

Operating instructions MA704: www.staubli.com/re-downloads.html

For crimping closed crimp contacts (O-Crimp)

PV-KxT4/5...-UR or PV-KxT4/8II-UR

• Place the contact in the appropriate cross-section range.
• For PV-KxT4/5... and PV-KxT4/8...: Place contact into the appropriate locator position, based on conductor cross-section to be crimped.

Operating instructions MA251 or MA704: www.staubli.com/re-downloads.html

Crimping Process

• Press the crimping pliers gently together until the crimping flaps are properly located within the crimping die.

The distance x between the crimped contact and the wire insulation must be maintained.

• Insert the stripped lead end until the lead strands come up against the locator.
• Completely close the crimping pliers.
• Open the crimping pliers and the clamp to remove the crimped lead.

Visual Crimp Check (IEC 60352-2)

Confirm that:

• all of the strands have been captured in the crimp sleeve
• the crimp sleeve is not deformed or missing any portion of the crimp flaps
• that the crimp is symmetrical
• a "brush" of conductor strands are visible on the contact side of crimp.

Assembly check

• Insert the crimped contact into the insulator of the male or female coupler until engaged. You will typically hear a "click" sound once fully engaged.
• Pull gently the cable to verify that the metal part is correctly engaged.
• Insert the appropriate end of the test pin into the male or female coupler as far as it will go. If the contact is assembled properly the white mark on the test pin must still be visible.

Cable gland assembly

• Pre-tighten cable gland with open-end spanner.
• Tighten cable gland using the torque tool set while holding up the insulator front with assembly and unlocking tool. The tightening torque must be appropriate for the solar cables used. Typical values are between 3.4 Nm and 3.5 N m¹).

¹ Stäubli recommends to use a calibrated torque wrench for assembly. The NFPA National Electric Code (NEC 2017) requires the use of a calibrated torque wrench in section 110.14(D).

For assembly of components an ambient temperature between -15 °C and 35 °C is recommended.

⚠️ Do not bottom out the capnut.

Mating and disconnecting the cable coupler

Without safety lock clip PV-SSH4

Mating

• Mate the connectors until a "click" can be heard.
• Check correct engagement by gently pulling the connector (maximum pulling force: 20 N).

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.

Disconnecting

• Use assembly and unlocking tool to disconnect.

With safety lock clip PV-SSH4

Mating

• Mate the connectors until a "click" can be heard.
• Check correct engagement by lightly pulling on the connector (maximum pulling force: 20 N).

Disconnecting

• Push the unlocking pins of assembly and unlocking tool into the openings provided in PV-SSH4 and onto the locking clips of the socket.
• Separate the connectors.

Technical data

¹ Cables connected to the connector shall be suitable for use in photovoltaic systems and shall comply with the requirements of IEC 62930.

²) IEC DC 1500 V: only for use in PV-systems in access-restricted areas.

³) For applicable cable diameter please see table 3 in this assembly instructions.

⁴) Engineering considerations: Application associated current ratings have to be verified in the products end-use and shall not exceed the maximum operating temperature.

⁵) The connector is considered to be in compliance with UL6703, Edition 1, Revision Date 06/10/2021 only when assembled in the manner specified by these assembly instructions.

⁶) The PV connectors have also been certified as cULus Listed products even if the UL Recognized Component Mark (UR) is molded on the PV connector housing.

Product overview

1. Socket (Douille)

• PV-KBT4/2.5...-UR
• PV-KBT4/6...-UR
• PV-KBT4/10...

2. Contact

5. Socket (Douille)

• PV-KBT4/5...-UR
• PV-KBT4/8II-UR

6. Contact

3. Plug (Broche)

• PV-KST4/2.5...-UR
• PV-KST4/6...-UR
• PV-KST4/10...

4. Contact

7. Plug (Broche)

• PV-KST4/5...-UR
• PV-KST4/8II-UR

8. Contact

Optional accessories

9. Socket sealing cap (Bouchon de protection)

• PV-BVK4

11. Safety lock clip (Clip de sécurité)

• PV-SSH4

10. Plug sealing cap (Bouchon de protection)

• PV-SVK4

Notes

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

Manufacturer Information

Fabricant/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
www.staubli.com/electrical