Stäubli MC4-Evo 2 Connector Assembly Instructions

Product Overview

This section provides a general overview of the MC4-Evo 2 connector. It includes illustrations of the female socket and male plug, along with optional accessories like socket and plug sealing caps (PV-BVK4, PV-SVK4).

Illustration: Female connector (socket) and male connector (plug) with cable entry points. Optional sealing caps for socket and plug.

Safety Instructions

Importance of the assembly instructions

⚠️ WARNING: Failure to follow assembly and safety instructions can result in life-threatening injuries due to electric shock, electric arcs, fire, or system failure.

• Follow all instructions.
• Use and install only according to these instructions and technical data.
• Safely store and pass on instructions 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 LVDC applications, though requirements may differ.

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

Requirements for Personnel

Assembly, installation, and commissioning must be performed by an electrician or an electrically instructed person.

Prerequisites for Installation and Assembly

• NEVER use a damaged product.
• ONLY use Stäubli-approved tools, materials, and auxiliary means.
• ONLY assemble approved PV cables 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.
• NEVER disconnect under load.
• NEVER connect Stäubli connectors with connectors from other manufacturers.
• NEVER mate contaminated connectors.
• A tool is required to open the 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 Note: If the connector is used in low-voltage DC applications other than PV arrays, consult the Stäubli Technical Description Report.

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 chemicals.

Cable Routing and Wire Management

Cable management must allow a minimum of 20 mm of cable exiting directly from the cable seal without bending or stress. ➡️ [Diagram: Cable exiting connector seal with 20mm straight length]

Do not allow the connector to be at the lowest point of cabling where water can collect.

Refer to cable manufacturers' specifications for minimum bending radius.

Contaminated/Damaged Connectors

• Prevent contamination from the environment (soil, water, insects, dust).
• Prevent contamination of the connector surface (stickers, paint, heat shrink tubing).
• Do not place connectors directly on roofing surfaces.
• Do not allow connectors to be in standing water.
• Do not mount cable ties directly on the connector body.

Mechanical Stress

• Check that connectors are not subjected to 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.

Thermal Stress

• Ensure the connector is not exposed to excessive thermal stress.
• Install to ensure sufficient heat dissipation.
• Installation in areas restricting airflow (e.g., large bundles, split cable harnesses, housings) is not permitted.
• Direct burial of the connector is not permitted.

Tools

The following tools are required for assembly:

• Illustration 1: Stripping pliers PV-AZM... with built-in stripping blades and 2.5 mm Allen key. (Type: PV-AZM-156 for 1.5-6 mm², PV-AZM-410 for 4-10 mm²)
• Illustration 2: Crimping pliers PV-CZM... and locator. (Crimping range: 2.5-6 mm² for PV-CZM-61100; 4-10 mm² for PV-CZM-60100. Locator: PV-LOC-MC4-EVO 2)
• Illustration 3: Assembly and unlocking tool PV-MS-PLS (Order No. 32.6058) or Open-end spanner set PV-MS (Order No. 32.6024).
• Illustration 4: Torque tool set PV-WZ-TORQUE-SET (Order No. 32.0065) or 17 mm torque wrench.
• Illustration 5: Test plug PV-EVO-PST (Order No. 32.6073).
• Illustration 6: Cable cutter PV-WZ-KS (Order No. 32.6080).

Refer to operating instructions for specific tools (e.g., MA267, MA704, MA270, MA705) available at www.staubli.com/re-downloads.html.

Storage

• Store components at a constant temperature between -30 °C and +60 °C with relative humidity below 70%.
• Do not expose to direct rainfall, condensation, or similar moisture.
• Keep away from acids, alkalis, gases, acetone, or other chemically aggressive substances.

Cable Preparation

Use flexible stranded wire cables of class 5 and 6. Use only tinned copper cables.

Attention: Do not use oxidized or bare conductors. Stäubli PV cables use high-grade tinned conductors. Stäubli prohibits the use of PVC cables and non-tinned cables of type H07RN-F for safety reasons.

Illustration 7: Check dimensions A and b according to illustration and Table 1/2.

Guideline for Connector Configuration

ℹ️ Note: If the cable diameter is between two limits, use the smaller seal.

The usable seals can be distinguished by color:

• DI: Maroon
• DX: Yellow
• DII: Grey

Product Configuration

1. MC4-Evo 2 Configuration with TÜV Rheinland Certification

Cables must be suitable for PV systems and comply with IEC 62930. Use Table 1 for configuration with TÜV Rheinland or TÜV Rheinland/UL certified cables.

Usable Seals: DI (Maroon), DX (Yellow), DII (Grey)

1) For systems > DC 1000 V, the PV cable sheath material must meet insulation class 1 per IEC 60664-1.

2. MC4-Evo 2 Configuration with UL Certification

Cables must be suitable for PV systems and comply with ZKLA (PV-wire) or TYLZ (USE-2). Use Table 2 for configuration with UL certified cables only.

Usable Seals: DI (Maroon), DX (Yellow), DII (Grey)

Attention: Do not assemble to single jacket cross-linked polyethylene cable (XLPE cable). This does not fulfill UL 6703 strain relief requirements.

Note for Canada: Installation must comply with CSA C22.1-2021. Connectors are intended for cables with ampacity based on conductor temperature of 75°C or higher. Suitable only for Class B and C stranded copper conductors (See NFPA NEC 70, Chapter 9, Table 10, Edition 2023).

Stripping the Cable

Illustration 8: Strip cable insulation down by 6.0 mm to 7.5 mm.

Attention: Do not cut individual strands during stripping!

Crimping

Illustration 9: Open clamp (K), insert contact into appropriate cross-section range, turn crimping flaps (C) upwards, release clamp (K). The contact is locked.

Note: Ensure the contact is placed in the housing and held by the clamp.

Illustration 10: Verify crimping flaps are correctly aligned. Press pliers gently together until flaps are properly located within the die.

Illustration 11: Insert stripped lead end until strands touch the locator. Completely close crimping pliers, open them, and remove the crimped cable assembly.

Assembly Check

Illustration 12: Visually check the crimp according to IEC 60352-2 criteria. Confirm all strands are captured, the sleeve is not deformed, the crimp is symmetrical, and a "brush" of conductor strands is visible.

Illustration 13: Insert crimped contact into the insulator until it clicks. Pull gently on the cable to verify correct engagement.

Illustration 14: Insert the test pin into the male or female coupler. The white mark on the test pin must remain visible if the contact is correctly located.

Illustration 15: Pre-tighten cable gland with PV-MS-PLS. Tighten cable gland using PV-WZ-Torque-Set while supporting the insulator front with PV-MS-PLS.

Note: Ambient temperature for assembly: -15 °C to 35 °C. Tightening torque must be adapted to the PV cable used. Stäubli recommends using a calibrated torque wrench, as required by NFPA NEC 2017 (Section 110.14(D)).

Mating and Disconnecting

Illustration 16: Mating

• Mate the cable coupler until an audible "click" is heard.
• Check correct engagement by lightly pulling on the connector (max. 20 N pulling force).

Attention: Partially engaged connectors are not permitted, as this can cause permanent clip deflection and loss of locking function. Always verify correct assembly.

ℹ️ Note: Unmated connectors must be protected from contamination using Stäubli sealing caps.

Illustration 17: Disconnecting

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

ℹ️ Note: Do not bottom out the capnut.

Technical Data

¹⁾ The connectors have been evaluated with cable types ZKLA (PV-wire) or TYLZ (USE-2). The cross-sections to be used, please refer to table 2 on page 6 of this assembly instructions.

²⁾ 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.

³⁾ 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.

Notes

This section is for additional notes.