Stäubli MC4-Evo ready connector MA293 (en) assembly instructions
Valid for: PV-KST4-EVO READY, PV-KBT4-EVO READY
Overview
This document provides assembly instructions for the Stäubli MC4-Evo ready connector, model MA293. It covers safety, tools, cable preparation, assembly, mating, disconnecting, and technical data.
Product Images
Image of a female MC4-Evo ready cable coupler (model PV-KBT4-EVO READY, part number 32.0030).
Image of a male MC4-Evo ready cable coupler (model PV-KST4-EVO READY, part number 32.0029).
Optional Accessories
Image of a sealing cap for female cable coupler (model PV-BVK4, part number 32.0716).
Image of a sealing cap for male cable coupler (model PV-SVK4, part number 32.0717).
Safety Instructions
Importance of the assembly instructions
⚠️ Attention: 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.
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.
Do NOT modify or repair component
- Mount connector only once.
- Do NOT modify connectors after assembly.
- Replace defective connectors.
Tools Required
(ill. 1) Stripping pliers
Image of stripping pliers (model PV-AZM-156/PV-AZM-410).
| Conductor cross section [mm²] | AWG | Type | Order No. |
| 1.5/2.5/4/6 | 4/6/10 | PV-AZM-156 | 32.6027-156 |
| PV-AZM-410 | 32.6027-410 |
ℹ️ Note: Operating instructions MA267 available at www.staubli.com/re-downloads.html.
(ill. 2) Unlocking tool
Image of an unlocking tool for MC4-Evo 2 (model PV-MS-MC4-EVO 2, Order No.: 32.6066).
(ill. 3) Recommended tooling
Image of an open-end spanner set for MC4-Evo ready (model MC4-MS-EVO READY, Order No.: 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 shall comply with the requirements of IEC 62930. The 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 the use of non-tinned cables of type H07RN-F.
(ill. 4) Stripping
Use the stripping pliers and remove the cable insulation by 15 mm up until 16.5 mm.
⚠️ Attention: Do not damage nor cut any strands when stripping the cable.
(ill. 5) Length check
ℹ️ Note: The length can be checked using the assembly key (according to the figure on the left, ill. 5).
(ill. 6) Twisting strands
Use 2 fingers and gently twist the strands and by doing this compress the strands to one twisted shape.
⚠️ Attention: Misaligned or missing strands could lead to an increased contact resistance.
Connector Assembly
(ill. 7) Cable insertion and locking
Insert the cable straight into the connector.
The cable latches (with an audible "click").
(ill. 8) Confirm the latch mechanism
Gently pull the cable.
The cable should not protrude the connector when slightly pulling.
Fastening the connectors
(ill. 9) Bottom out the nut for this product (with a torque of approx. 3 – 4 Nm).
ℹ️ Note: It is feasible to screw the connector manually. Yet, it is recommended to use the set of assembly tools (see ill. 3) to carry out this manufacturing step.
(ill. 10)
⚠️ Attention: The IP (ingress protection) class – when plugged in – is only guaranteed if the connector has been assembled on correctly!
Mating and Disconnecting the Cable Coupler
(ill. 11 + ill. 12) Mating
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 has to be verified.
Check that the connectors are correctly engaged by slightly pulling on the connectors.
ℹ️ Note: Unmated connectors must be protected from any contamination using Stäubli sealing caps.
(ill. 13 + ill. 14) Disconnecting
Push the unlocking tool onto the clips.
Disconnect the previously mated connectors.
Notes on Installation
Diagram showing excessive cable bending close to the connector (marked with red X).
Diagram showing proper cable routing with a minimum bend radius of 20 mm (marked with green checkmarks).
Technical Data
| Type designation | PV-KST4-EVO READY PV-KBT4-EVO READY |
| Connector system | Ø 4 mm |
| Rated voltage | DC 1500 V (IEC 62852:2014+Amd.1:2020)1) |
| Rated current | 30 A |
| Rated impulse voltage | DC 16 kV (1500 V) |
| Ambient temperature range | -40 °C ... +85 °C (IEC) |
| Transportation/storage temperature range | -30 °C ... +60 °C |
| Transportation/storage relative humidity | < 70 % |
| Upper limiting temperature | 115 °C (IEC) |
| Degree of protection, mated | IP65/IP68 (1 m, 1 h) |
| Degree of protection, unmated | IP2X |
| Overvoltage category | III |
| Contact resistance of plug connectors | < 0,5 m℉ |
| Polarity of connectors | Socket = positive / Plug = negative |
| Locking system | Locking-type |
| Class (IEC) | II |
| Type of termination | Spring clamp (tool free connection) |
| Safety instruction | Do not disconnect under load |
| Contact material | Copper, tin plated |
| Insulation material | PA |
| Mateable with connector type | Tested exclusively in connection with connectors from the MC4 product family. |
1) The connectors are to be used with cables according to the following table (Tab. 1)
| Allowed cable type | Wire cross-section [mm²] | Outer diameter [mm] |
| PV cable according IEC 62930:2017 or EN 50618:2014 | 4.0/6.0 | 5.4 – 7.6 |
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
