Stäubli MC4-Evo 2 Branch Connectors: Assembly and Technical Guide
Product Overview
This document provides assembly instructions and technical data for the Stäubli MC4-Evo 2 series of branch connectors, including branch plugs and branch sockets. These connectors are designed for reliable electrical connections in DC circuits, commonly used in photovoltaic systems.
Branch Plug MC4-Evo 2
Type: PV-AZS4-EVO 2-UR
Order No.: 32.0197
Branch Socket MC4-Evo 2
Type: PV-AZB4-EVO 2-UR
Order No.: 32.0196
Sealing Caps
PV-BVK4 (Order No. 32.0716) for sockets
PV-SVK4 (Order No. 32.0717) for plugs
Intended Use
Branch connectors MC4-Evo 2 are used to connect two MC4/MC4-Evo 2 plugs or two MC4/MC4-Evo 2 sockets in parallel. Each branch connector features three terminals for this purpose. They are primarily used in DC circuits of photovoltaic arrays but can also serve as low-voltage DC components in other applications.
Safety Instructions
Importance of Assembly Instructions
Failure to follow these instructions can lead to life-threatening injuries from electric shock, arc flash, fire, or system failure. Always adhere to all assembly instructions and technical data. Store these instructions safely and pass them on to subsequent users.
Requirements for Personnel
Assembly, installation, and commissioning must only be performed by a qualified electrician or an electrically instructed person. An electrician possesses the necessary training, knowledge, and experience to identify and avoid electrical hazards and use appropriate personal protective equipment.
Prerequisites for Installation and Assembly
- Never use an obviously damaged product.
- Only use tools and procedures approved by Stäubli.
Safe Assembly and Mounting
Live parts can remain energized after isolation or disconnection. Ensure the photovoltaic array or string is de-energized before installing the product.
Mating and Disconnecting
- Always de-energize the photovoltaic system before mating and disconnecting connectors.
- Never disconnect connectors under load.
- Do not connect male or female parts of Stäubli connectors with connectors from other manufacturers.
Do Not Modify or Repair Component
- Mount the connector only once.
- Do not modify connectors after assembly.
- Replace defective connectors.
Installation and Assembly
Tools Required
Illustration 1 shows the required tools: PV-MS-PLS/2 (Order No. 32.6058) or PV-MS-MC4-EVO (Order No. 32.6066).
Refer to Operating Instructions MA270 at www.staubli.com/electrical for more information.
Connection and Disconnection
Plugging
Illustration 2: Plug the connector parts together until they click into place. Verify proper engagement by pulling on the connector.
[Attention] Assembly of connectors that are not fully engaged is not permitted, as this could lead to permanent deflection of clips and potential loss of the locking function. Assembly must always be verified.
Unplugging
Illustration 3: To disconnect, unlock the locking clip using the PV-MS-PLS/2 or PV-MS-MC4-Evo tool and pull the connector apart.
Options/Accessories
Illustration 4: Unplugged connectors must be protected from contamination using sealing caps. PV-BVK4 (Order No. 32.0716) is for sockets, and PV-SVK4 (Order No. 32.0717) is for plugs.
Example of Parallel Connections
Diagram (Illustration 5) shows the parallel connection of solar modules. Strings of modules are connected in parallel using branch connectors, with connections routed to an inverter. Ensure that strings are correctly interconnected.
[Attention] When connecting connectors, ensure that the rated data (current carrying capacity and rated voltage) of the branch connectors are compatible with the connectors used, as detailed in Tables 1 and 2. Also, observe the assembly instructions for the connectors attached to the MC4-Evo 2 branch connectors.
Product Specification in relation to Certified Mating Correlation
The rated voltage, rated current, and upper limiting temperature are limited by the corresponding mating connector from Stäubli. Detailed specifications are provided in Tables 1 and 2.
Table 1: TÜV Rheinland
| Type | MC4 | MC4-Evo 2 |
|---|---|---|
| Rated Voltage IEC | PV-KST4/xy-UR; PV-KST4/10y PV-KBT4/xy-UR; PV-KBT4/10y |
PV-KST4-EVO 2/xy-UR; PV-KST4-EVO 2A/xy PV-KBT4-EVO 2/xy-UR; PV-KBT4-EVO 2A/xy |
| DC 1000 V | DC 1500 V | |
| Rated Current IEC | 22 A (2.5 mm²) 39 A (4 mm²) 39 A (6 mm²) 45 A (10.0 mm²) |
39 A (2.5 mm²) 45 A (4 mm²) 53 A (6 mm²) 60 A (10.0 mm²) |
| Upper Limit Temperature (ULT) | 105 °C | 115 °C |
Table 2: UL
| Type | MC4 | MC4-Evo 2 |
|---|---|---|
| Rated Voltage UL | PV-KST4/xy-UR PV-KBT4/xy-UR |
PV-KST4-EVO 2/*-UR; PV-KST4-EVO 2A/* PV-KBT4-EVO 2/*-UR; PV-KBT4-EVO 2A/* |
| DC 1500 V | DC 1500 V | |
| Rated Current UL | 30 A (AWG14) 35 A (AWG12) 50 A (AWG10) 50 A (AWG8) |
30 A (AWG14) 35 A (AWG12) 50 A (AWG10) 50 A (AWG8) |
| Max. Operating Temperature (MOT) | 85 °C | 85 °C |
(Tab. 2) The ampacity rating of these products is limited based on the smallest used wire diameter per the National Electrical Code (NEC) requirements for outdoor applications considering the correction factor.
Notes on Installation
General Notes
- The MC4-Evo 2 branch connectors have a hole in the middle of each component, which can be used to fix the connector with cable ties.
- For low-voltage DC applications other than photovoltaic systems, consult the Stäubli Technical Description Report. [Link to www.staubli.com/electrical]
- Unmated connectors must be protected from environmental impact (moisture, dirt, dust, etc.) using 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.
Contaminated/Damaged Connectors
- Prevent contamination from the environment (e.g., soil, water, insects, dust).
- Ensure the connector surface is not contaminated (e.g., with stickers, paint, heat shrink tubing).
- Do not allow the connector to be directly on the roofing surface.
- Position the connector away from the lowest point of cabling where water can collect.
- Avoid placing the connector in standing water.
- Do not mount cable ties directly on the connector body.
Mechanical Stress
- Ensure connectors are not subjected to permanent mechanical tensile load or vibration.
- Connectors should not be strained by cable management.
- Ensure locking clips are not subjected to excessive mechanical force.
Note for Transportation and Repacking
Ensure that the locking clips are not subjected to excessive mechanical force during transportation and repacking.
Technical Data
| Parameter | Value |
|---|---|
| Type designation | PV-AZB4-EVO 2-UR, PV-AZS4-EVO 2-UR |
| Rated voltage | DC 1500 V |
| Test voltage | 8 kV 3) |
| Rated current (IEC) | 60 A 1) |
| Rated current (UL) | 50 A 2) |
| Rated impulse voltage | 16 kV |
| Ambient temperature range (IEC) | -40 °C ... +85 °C |
| Ambient temperature range (UL) | -40 °C ... +85 °C |
| Transportation/storage temperature range | -40 °C ... +60 °C |
| Max. operating temperature (UL) | +85 °C |
| Transportation/storage relative humidity | < 70% |
| Upper limiting temperature | 115 °C 1) |
| Degree of protection, mated | IP65/IP68 (1 m, 1 h) |
| Degree of protection, unmated | IP2X |
| Overvoltage category/Pollution degree | CAT III / 3 |
| Contact resistance of plug connectors | < 0.5 mΩ |
| Locking system | Locking type II |
| Safety class | MULTILAM |
| Contact system | Cuivre, étamé/Copper, tin plated |
| Contact material | PA |
| Insulation material | UL94-V0 |
| Flame class | R 60149724 |
| TÜV Rheinland certified according to IEC 62852:2014/AMD1:2020 | E343181 |
| UL certified according to UL6703 | Original MC4 cable connectors Original MC4-Evo 2 cable connectors |
| Compatible with connector type | 5000 m; AK 60159400 |
| Max. operating altitude above sea level | Level 2; AK 60158914 |
| Temperature Level according to IEC TS 63126 | CE declaration of conformity |
1) The current and voltage ratings, as well as the upper limiting temperature are limited to the corresponding mating connector from Stäubli. For detailed specification refer to Tab. 1, page 5.
2) The current and voltage ratings, as well as the upper limiting temperature are limited to the corresponding mating connector from Stäubli. For detailed specification refer to Tab. 2, page 5.
Engineering Considerations: Application associated current ratings have to be verified in the products end-use and shall not exceed the maximum operating temperature.
3) Rated voltage 1000 V and test voltage 6 kV with mated MC4 connector; 1500 V and test voltage 8 kV with mated MC4-Evo 2 connector.
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
Website: www.staubli.com/electrical
