Stäubli MC4-Evo 2 Connector (MA273) Assembly and Safety Instructions

Product Overview

The Stäubli MC4-Evo 2 connector is a reliable solution for photovoltaic systems. This document provides assembly and safety instructions for the MA273 model.

Product Components:

• Female Connector (Socket): PV-KBT4-EVO 2-UR
• Male Connector (Plug): PV-KST4-EVO 2-UR

Optional Accessories:

• Socket sealing cap (PV-BVK4)
• Plug sealing cap (PV-SVK4)

Safety Instructions

Importance of Assembly Instructions: Failure to follow these instructions can lead to life-threatening injuries from electric shock, electric arcs, fire, or system failure.

• Always follow all assembly instructions.
• Use and install the product only according to these 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. It can also be used for other low-voltage DC applications, though specific requirements may differ.

Requirements for Personnel: Assembly and installation must be performed only by a qualified electrician or an electrically instructed person.

Prerequisites for Installation and Assembly:

• Never use an obviously damaged product.
• Only use tools, materials, and auxiliary means approved by Stäubli.
• Only assemble approved PV cables to the connector.

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 the connectors.
• Never disconnect the connectors under load.
• Never connect Stäubli connectors with connectors from other manufacturers.
• Never mate contaminated connectors.
• A tool is required to open locking-type connectors.

Do Not Modify or Repair Components:

• 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, etc.) with sealing caps.
• Do not mate contaminated connectors.
• Connectors must not come into contact with any chemicals.
• Install connectors to minimize exposure to direct sunlight.

Cable Routing and Wire Management:

• Cable management must allow a minimum of 20 mm of cable exit from the cable seal without bending or stress.
• Do not position the connector at the lowest point of cabling where water can collect.
• Refer to cable manufacturer specifications for minimum bending radius.

Contaminated/Damaged Connectors: Ensure connectors are not contaminated by environmental substances (e.g., soil, water, insects, dust). Avoid contamination on the connector surface (e.g., stickers, paint, heat shrink tubing). Do not place connectors directly on roofing surfaces or in standing water. Do not mount cable ties directly on the connector body.

Mechanical Stress: Connectors shall not be under strain from cable management. Ensure connectors are not subjected to permanent mechanical tensile load or vibration. Constrain connectors from dynamic movement and isolate from mechanical load, e.g., from moving components of a PV-Tracker system.

Thermal Stress: Ensure connectors are not exposed to excessive thermal stress. Install for sufficient heat dissipation. Installation in areas restricting airflow (e.g., large bundles, split cable harnesses, other housings) is not permitted. Direct burial of the connector is not permitted.

Tools Required

The following tools are recommended for assembly:

• Stripping Pliers PV-AZM... (Order No. 32.6027-156): Includes built-in stripping blades and 2.5 mm Allen key.
• Crimping Pliers PV-CZM... and Locator (e.g., PV-CZM-61100, Order No. 32.6020-61100; Locator PV-LOC-MC4-EVO 2, Order No. 32.6084): For crimping and positioning.
• Assembly and Unlocking Tool PV-MS-PLS (Order No. 32.6058) or Open-end Spanner Set PV-MS (Order No. 32.6024): For assembly and unlocking.
• Torque Tool Set PV-WZ-TORQUE-SET (Order No. 32.0065) or Torque Wrench 17 mm: For tightening cable glands.
• Test Plug PV-EVO-PST (Order No. 32.6073): For testing.
• Cable Cutter PV-WZ-KS (Order No. 32.6080): For cutting cables.

Refer to individual operating instructions for each tool for detailed usage.

Storage

Store components at a constant temperature between -30°C and +60°C with relative humidity below 70%. Protect from moisture, acids, alkalis, gases, and acetone.

Connector Configuration Guidelines

Cables connected to the connectors must be suitable for photovoltaic systems and comply with relevant standards (IEC 62930, UL, CSA).

TÜV Rheinland Certification:

Select configurations based on cable type, conductor cross-section, and reference dimension as per Table 1. Seals (DI, DX, DII) are color-coded (Maroon, Yellow, Grey).

Note: For DC > 1000V systems, ensure PV cable sheath material meets insulation class 1 per IEC 60664-1.

UL Certification:

Select configurations based on cable type (ZKLA, TYLZ/USE-2), conductor cross-section, and reference dimension as per Table 2. Seals are color-coded.

Cable Preparation

For IEC applications, use flexible conductors class 5 or 6 (IEC 60228). For UL applications, use class B or higher power cables.

Attention: Use only tinned copper conductors. Do not use uncoated or oxidized conductors. Stäubli prohibits the use of PVC cables and non-tinned H07RN-F cables.

Steps:

• Check dimensions A and b according to Tables 1 and 2.
• Select the correct configuration based on seal color (DI: Maroon, DX: Yellow, DII: Grey).
• Strip cable insulation to 6.0 mm to 7.5 mm. ⚠️ Attention: Do not cut individual strands during stripping.

Crimping

Follow these steps for proper crimping:

1. Open the crimping tool clamp (K) and insert the contact into the correct cross-section range, ensuring it is fully in the positioning device.
2. Turn the crimping flaps (C) upwards to form a "U" shape.
3. Release the clamp (K); the contact is locked. ℹ️ Note: Ensure the contact is seated in the housing and held by the clamp.
4. Gently press the crimping pliers together until the flaps are correctly positioned in the die.
5. Insert the stripped cable end until the strands reach the locator.
6. Completely close the crimping pliers.
7. Open the pliers and clamp to remove the crimped lead.
8. Visually check the crimp against IEC 60352-2 criteria: all strands captured, sleeve not deformed, symmetrical crimp, visible "brush" of strands on the contact side.

Assembly Check

Mating Contacts:

• Insert the crimped contact into the male or female insulator until it clicks into place.
• Gently pull the cable to verify the metal part is correctly engaged.
• Insert the appropriate end of the test pin into the coupler. The white mark on the test pin should remain visible if assembled correctly.

Tightening Cable Gland:

• Tighten the cable gland using a torque tool, supporting the insulator front with the assembly/unlocking tool.
• Recommended ambient temperature for assembly: -15°C to 35°C. Adjust torque based on the specific PV cable used (refer to Table 3).
• ℹ️ Note: Calibrate torque wrench before use.
• ℹ️ Note: Do not bottom out the capnut.

Mating and Disconnecting

Mating:

• Connect connectors until a "click" is heard.
• Verify correct engagement by gently pulling (max 20 N). ⚠️ Attention: Partially engaged connectors can cause permanent clip deflection and loss of locking function. Ensure correct assembly.
• ℹ️ Note: Protect unmated connectors from contamination using Stäubli sealing caps.

Disconnecting:

• Use the assembly and unlocking tool to disconnect.

Technical Data

Notes on certifications and cable types are provided in the original document.

Manufacturer Information

Manufacturer: Stäubli Electrical Connectors AG

Address: Stockbrunnenrain 8, 4123 Allschwil/Switzerland

Contact: Tel. +41 61 306 55 55, Fax +41 61 306 55 56, Email: ec.ch@staubli.com

Website: www.staubli.com/electrical