Stäubli MC4-Evo 2 MA299 Panel Receptacle 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 photovoltaic array. The connector can be used for purposes other than those in a photovoltaic array, 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.

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 and procedures 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 photovoltaic-array or -string is de-energized.

Mating and disconnecting

• ALWAYS de-energize the photovoltaic 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.

Do NOT modify NOR repair component

• Mount connector only once.
• Do NOT modify connectors after assembly.
• Replace defective connectors.

Tools Required

(ill. 1) Stripping pliers PV-AZM...

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

(ill. 2) Crimping pliers PV-CZM... incl. locator and crimping die.

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

(ill. 3) PV-MS-PLS Assembly and unlocking tool, Open-end spanner set PV-MS

PV-MS-PLS Assembly and unlocking tool, 1 Set = 2 pcs. Order No. 32.6058

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

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

(ill. 4) PV-WZ-Torque-Set, Torque wrench 17 mm

PV-WZ-Torque-Set, Order No. 32.0065, or Torque wrench 17 mm

(ill. 5) Test plug PV-EVO-PST

Test plug PV-EVO-PST, Order No. 32.6073

(ill. 6) Cable cutter PV-WZ-KS

Cable cutter PV-WZ-KS, Order No. 32.6080

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

Cable Preparation

Cables with a strand class 5 and 6 shall be connected. Use tinned copper cables only.

Attention: Do not use oxidized nor bare (i.e. uncoated) conductors. All Stäubli solar cables have high grade tinned conductors. For safety reasons, Stäubli prohibits the use of PVC cables and the use of non-tinned cables of type H07RN-F.

Stripping

(ill. 7) Check dimension b in accordance with ill. 7 and Tab. 1.

Note: Please use the smaller sealing if the cable diameter used is between two limits.

Note: 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 MC4-Evo 2. Link

Stripping dimensions

(ill. 8) Strip cable to dimension 6.0 mm to 7.5 mm.

Attention: Do not cut individual strands when stripping!

Crimping

(ill. 9) Contact placement

• Open and hold the clamp (K).
• Place the contact in the appropriate cross-section range.
• Turn the crimping flaps upwards.
• Release clamp (K).
• The contact is locked.

Note: Make sure that the contact is placed in the housing and is held by the clamp.

(ill. 10) Applying pressure

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

(ill. 11) Inserting cable

Insert the stripped cable end until the cable strands come up against the locator. Completely close the crimping pliers.

(ill. 12) Visual check

Visually check the crimp according to the criteria written in IEC 60352-2:2006 + A1:2013. 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.
• The crimp is symmetrical.
• A "brush" of conductor strands are visible on the contact side of crimp.

Installation of Receptacles

(ill. 13) Housing preparation

Manage breakthroughs/drill housing plate using dimensions as layed out in ill. 13. For both horizontal and vertical mounting a spacing (X) of at least 25 mm is recommended.

Note: Ensure a housing wall thickness of 2-4 mm for metal housings and 2-6 mm for plastic housings. In case of using a wall thickness outside the values mentioned above the validation process has to be done by the installer.

(ill. 14) Gasket placement

Attention: Before mounting the plastic insulations through the bore, the flat gasket must be located on the insulation.

Danger: In case of lacking flat gasket or incorrect mounting, the ingress protection IP65 and IP68 is not ensured!

(ill. 15) Securing the receptacle

Position the plastic parts (E) such that they can be plugged and unplugged. Screw on the nuts (M) and tighten them with the torque wrench. Typical values are about 1.7 N m¹). The appropriate torque has to be verified in the end-use according to the housing chosen.

¹⁾ Follow the calibration procedure defined for the applied torque wrench!

In mounting position the flat gasket must lie even on the outer side of the mounting surface. During visual check following the assembly steps, no cracks, foldings or other irregularities shall exist.

Assembly Check

(ill. 16) Contact engagement

Insert the crimped contact into the insulator of the male or female coupler until engaged. You will typically hear a "click" sound once fully inserted. Pull gently on the cable to check that the metal part is correctly engaged.

(ill. 17) Test pin verification

Insert the appropriate end of the test pin into the male or female coupler as far as it will go. If the contact is correctly located the white mark on the test pin must still be visible.

(ill. 18) Polarity marking

The polarity of the PV-string in its end-use has to be marked, for example on the PCE enclosure where the panel receptacles are mounted.

Note: The following markings for polarity are deemed to be sufficient: "+" and "-", "POS" and "NEG", "POSITIVE" and "NEGATIVE".

Mating and Disconnecting

Mating

(ill. 19) Mate the connectors until a "click" can be heard. Check correct engagement by lightly pulling the connector (maximum pulling force: 20 N).

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 assembly has to be verified at all times.

Disconnecting

Use PV-MS-PLS/2 or PV-MS to disconnect.

Notes on Installation

General notes on installation

• Unmated connectors must be protected from environmental impact (moisture, dirt, dust, etc.) with sealing caps (socket order no. 32.0716; plug order no. 32.0717).
• Do not mate contaminated connectors.
• Connectors must not come into contact with any chemicals.

Cable routing

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 specification for minimum bending radius.

[Diagram: Cable exiting seal with minimum 20mm length, no 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 that the connector is directly on the roofing surface.
• Do not allow that the connector is at the lowest point of cabling where water can collect.
• Do not allow that the connector is in standing water.
• Do not allow that 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.

Technical Data

Manufacturer Information

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

Website: www.staubli.com/electrical

Note: This document is subject to modifications.