Stäubli MC4-Evo Ready Connector Assembly Instructions
Model: MA293
Valid for: PV-KST4-EVO READY, PV-KBT4-EVO READY
Safety Instructions
Importance of the assembly instructions
Failure to follow the assembly and safety instructions could result in life-threatening injuries due to electric shock, electric arcs, fire, or system failure.
- Follow the entire assembly instructions.
- Use and install the product only according to these 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 dangers originating from electricity. An electrician must be 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 dangers originating 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 parts of Stäubli connectors with connectors from other manufacturers.
- NEVER mate contaminated connectors.
Do NOT Modify or Repair Components
- Mount connector only once.
- Do NOT modify connectors after assembly.
- Replace defective connectors.
Tools Required
Illustration 1: Stripping Pliers
Type: Stripping pliers PV-AZM...
| Conductor Cross Section (mm²) | AWG | Type | Order No. |
|---|---|---|---|
| 1.5/2.5/4/6 | 4/6/10 | PV-AZM-156 | 32.6027-156 |
| 4/6 | 4/6/10 | PV-AZM-410 | 32.6027-410 |
Note: For operating instructions MA267, visit www.staubli.com/re-downloads.html
Illustration 2: Unlocking Tool
Description: Unlocking tool for MC4-Evo 2
Type: PV-MS-MC4-EVO 2
Order No.: 32.6066
Recommended Tooling
Illustration 3: Assembly Spanner Set
Description: Open-end spanner set for MC4-Evo ready
Type: 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 must be suitable for photovoltaic systems and comply with IEC 62930. Flexible conductors must be class 5 or class 6 according to IEC 60228.
Attention: Use tinned copper conductors only. Do not use uncoated (bare) or oxidized conductors. Stäubli PV cables feature high-quality, tinned conductors. For safety reasons, Stäubli prohibits the use of PVC cables and non-tinned cables of type H07RN-F.
Illustration 4: Stripping Cable
Use the stripping pliers to remove the cable insulation by 15 mm up to 16.5 mm.
Attention: Do not damage strands when stripping the cable.
Illustration 5: Checking Strip Length
Note: The strip length can be checked using the assembly key (as shown in the figure to the left).
Illustration 6: Twisting Strands
Use two fingers to gently twist the strands and compress them into a single, twisted shape.
Attention: Misaligned or missing strands could lead to increased contact resistance.
Connector Assembly
Illustration 7: Cable Insertion and Locking
Insert the cable straight into the connector. The cable latches with an audible "click".
Illustration 8: Confirming the Latch Mechanism
Gently pull the cable. The cable should not protrude from the connector when pulled lightly.
Fastening the Connectors
Illustration 9: Tightening the Nut
Bottom out the nut for this product with a torque of approximately 3 - 4 Nm.
Note: It is feasible to screw the connector manually. However, it is recommended to use the assembly tool set (see Illustration 3) for this installation step.
Illustration 10: IP Class Guarantee
Attention: The IP (ingress protection) class, when plugged in, is only guaranteed if the connector has been assembled correctly!
Mating and Disconnecting the Cable Coupler
Illustrations 11 & 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 permanent deflection of the locking clips, potentially causing loss of the locking function. Verify correct mating.
Check that the connectors are correctly engaged by slightly pulling on them.
Note: Unmated connectors must be protected from contamination using Stäubli sealing caps.
Illustrations 13 & 14: Disconnecting
Push the unlocking tool onto the clips.
Disconnect the previously mated connectors.
Notes on Installation
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 any chemicals.
Cable Routing and Wire Management
Cable management must allow a minimum of 20 mm of cable to exit directly from the cable seal without bending or stress. Refer to the cable manufacturer's specification for minimum bending radius.
Diagram: Illustrates correct vs. incorrect cable bending near the connector. The correct method shows a minimum 20mm clearance from the connector, while the incorrect method shows excessive bending right at the connector.
Contaminated/Damaged Connectors
- Do not allow the environment to contaminate connectors (e.g., soil, water, insects, dust).
- Do not allow the connector surface to be contaminated (e.g., with stickers, paint, heat shrink tubing).
- Do not allow the connector to be directly on the roofing surface.
- Do not locate the connector at the lowest point of the wiring loom where water can accumulate.
- Do not allow the connector 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.
Technical Data
| Parameter | Value |
|---|---|
| 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) |
| 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 mΩ |
| Polarity of Connectors | Socket = Plus/positive, Plug = Minus/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 |
| TÜV Rheinland Certification | R 60174999 (Certified according IEC 62852:2014+Amd.1:2020) |
| Mateable with Connector Type | Tested exclusively in connection with connectors from the MC4 product family. |
Table 1: Allowed Cable Type
| Allowed Cable Type | Wire Cross-section [mm²] | Outer Diameter [mm] |
|---|---|---|
| PV cable according to IEC 62930:2017 or EN 50618:2014 | 4.0/6.0 | 5.4 - 7.6 |
Manufacturer Information
Manufacturer: Stäubli Electrical Connectors AG
Address: 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
