Stäubli MC4-Evo Ready-Connector MA293 Assembly Instructions

Safety Instructions

Importance of the assembly instructions: Failure to follow these instructions can lead to life-threatening injuries from electric shock, electric arcs, fire, or system failure. Always follow the complete instructions, use the product only as specified, and store instructions for future users.

Intended use: The connector electrically connects components within the DC circuits of a PV array.

Requirements for personnel: Assembly, installation, and commissioning must be performed by an electrician or an electrically instructed person. An electrician has professional training and experience to identify and avoid electrical hazards. An instructed person works under supervision.

Prerequisites for installation and assembly: Never use a damaged product. Only use Stäubli-approved tools and materials. Only use approved PV cables.

Safe assembly and mounting: Live parts can remain energized. Install the product only when the PV module is de-energized.

Mating and disconnecting: Always de-energize the PV system before mating or disconnecting. Never disconnect under load. Do not mix Stäubli connectors with other manufacturers' connectors. Never mate contaminated connectors.

Do NOT modify or repair component: Mount the connector only once. Do not modify connectors after assembly. Replace defective connectors.

Tools Required

Illustration (ill. 1): Shows a pair of stripping pliers, identified as PV-AZM... with order numbers 32.6027-156 and 32.6027-410 for different conductor cross-sections (1.5/2.5/4/6 mm² and 4/6/10 mm²).

Note: Refer to operating instructions MA267 available at www.staubli.com/re-downloads.html.

Illustration (ill. 2): Shows an unlocking tool for MC4-Evo 2, model PV-MS-MC4-EVO 2, order number 32.6066.

Illustration (ill. 3): Shows an open-end spanner set for MC4-Evo ready connectors, model MC4-MS-EVO READY, order number 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 must be suitable for photovoltaic systems and comply with IEC 62930. Conductors should be class 5 or 6 according to IEC 60228.

Attention: Use tinned copper conductors. Avoid bare or oxidized conductors. Stäubli prohibits PVC cables and non-tinned H07RN-F cables.

Illustration (ill. 4): Shows using stripping pliers to remove cable insulation to a length of 15 mm to 16.5 mm. An attention note warns not to damage strands.

Note: The correct length can be checked using the assembly key (ill. 5).

Illustration (ill. 6): Shows twisting the strands gently with two fingers to compress them into one shape. An attention note warns that misaligned or missing strands can increase contact resistance.

Connector Assembly

Illustration (ill. 7): Shows inserting the cable straight into the connector until it latches with an audible click.

Illustration (ill. 8): Shows gently pulling the cable to confirm the latch mechanism. The cable should not protrude when pulled lightly.

Fastening the connectors (ill. 9): Screw the nut until it bottoms out, with a torque of approximately 3-4 Nm. A note suggests using the assembly tools (ill. 3) for this step, although manual screwing is possible.

Illustration (ill. 10): An attention note states that the IP protection class (IP65/IP68 when mated) is only guaranteed if the connector is assembled correctly.

Mating and Disconnecting the Cable Coupler

Mating (ill. 11 + 12): Plug the line connectors together until they latch. An attention note warns that partially engaged connectors can lead to loss of locking function. Verify correct mating by gently pulling.

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

Disconnecting (ill. 13 + 14): Push the unlocking tool onto the clips and then disconnect the connectors.

Notes on Installation

General notes: Protect unmated connectors from environmental impact (moisture, dirt, dust) with sealing caps. Do not mate contaminated connectors. Keep connectors away from chemicals.

Cable routing and wire management: Allow a minimum of 20 mm of cable exiting the seal without bending or stress. Refer to cable manufacturer specifications for minimum bending radius.

Illustration: Shows a comparison between a cable bent too sharply near the connector ("Too much bend of cable close to connector") and proper cable routing ("Proper cable routing"), both indicating the minimum 20 mm clearance.

Contaminated/damaged connectors: Prevent contamination from the environment (soil, water, insects, dust) or surface contamination (stickers, paint, heat shrink tubing). Do not place the connector directly on roofing surfaces. Avoid locating the connector at the lowest point of the wiring loom to prevent water accumulation. Do not place connectors 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.

Technical Data

Table 1: Allowed cable type

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

Stäubli MC4 and MC4-Evo are registered trademarks of Stäubli.