ST UBLI MA251 Crimping pliers PV-CZM User Manual
- June 9, 2024
- ST UBLI
Table of Contents
ST UBLI MA251 Crimping pliers PV-CZM
Safety instructions
Importance of the instruction manual
NOT following the instruction manual and safety instructions could result in life-threatening injuries due to electric shock, electric arcs, fi re, or failure of the system
- Follow the entire instruction manual
Use the product only according to this instruction manual and the technical
data.
The digital instruction manual and the technical data are available at:
www.staubli.com/electrical
Intended use
The present hand tools are in place to deliver crimp excellence for Stabil PV
connectors with cables.
Crimping’s shall be carried out only in de-energized state of the cables.
The hand tool is NOT suitable for Live working (IEC 60900).
Safety instructions regarding the emergency opening feature to avoid human injuries:
Required tool for emergency opening:
Screwdriver with fine tip e.g. 3 × 75mm
Description of the emergency opening:
Use the screwdriver to turn the screw anti-clockwise or clockwise to a point
where the pliers will be disengaged instantly.
Note:
Once the crimping pliers have been opened using the emergency opening, the
metal crimp in process needs to be discarded.
No special action necessary to use the crimping pliers for any next crimp
operation following an emergency opening.
Explanation for MC4
(ill. 1)
Crimping pliers incl. locator and built-in crimping die.
PV-K8/10/12/14BT/10…, PV-KST/10…| PV-KBT4/8II-UR, PV-KST4/8II-UR| PV- KBT4/5…-UR, PV-KST4/5…-UR| PV-KBT4/6…-UR,
PV-KST4/6…-UR
| PV-KBT4/2,5…-UR,
PV-KST4/2,5…-UR
| Type
---|---|---|---|---|---
10 mm2| 8 AWG| 10 AWG| 12 AWG| 14 AWG| 10 AWG| 6 mm2| 12 AWG| 4 mm2|
14 AWG
|
2.5 mm2
| Conductor cross section
•| | | | | •| •| •| •|
•
|
•
| (B-Crimp) Open crimp contacts (B-Crimp)
| •| •| •| •| | | | | | | (O-Crimp) Closed crimp contacts (O-Crimp)
| | | | | | | •| •|
•
|
•
| PV-CZM-18100 32.6020-18100| Crimpzangen Crimping pliers
| | | | | •| •| •| •|
•
|
•
| PV-CZM-19100 32.6020-19100
| •| | | | •| •| •| •| | | PV-CZM-22100 32.6020-22100
| •| •| •| •| | | | | | | PV-CZM-23100 32.6020-23100
•| | | | | | | •| •| | | PV-CZM-20100 32.6020-20100
•| | | | | •| •| | | | | PV-CZM-21100 32.6020-21100
| | | | | | | •| •|
•
|
•
| PV-ES-CZM-18100 32.6021-18100| Crimpeinsätze Crimping dies
| | | | | •| •| •| •|
•
|
•
| PV-ES-CZM-19100 32.6021-19100
| •| | | | •| •| •| •| | | PV-ES-CZM-22100 32.6021-22100
| •| •| •| •| | | | | | | PV-ES-CZM-23100 32.6021-23100
•| | | | | | | •| •| | | PV-ES-CZM-20100 32.6021-20100
•| | | | | •| •| | | | | PV-ES-CZM-21100 32.6021-21100
•| | | | | •| •| •| •|
•
|
•
| PV-LOC 32.6040| Locator Locator
| •| | | | •| •| •| •| | | PV-LOC-B 32.6055
| •| •| •| •| | | | | | | PV-LOC-D 32.6074
Pos.| Cable cross section| suitable for
---|---|---
| mm2| AWG|
1| 1.5| 14| PV-KST4/2.5-UR PV-KBT4/2.5-UR
2| 2.5| | PV-KST4/2.5-UR PV-KBT4/2.5-UR
3| 4| 12| PV-KST4/6-UR PV-KBT4/6-UR
Individual parts
(ill. 2 + 3 + 4 + 5 + 6 + 7) Interchangeable crimping dies.
| Crimping range | Type | Order No. |
|---|---|---|
| mm2 | AWG | |
| 1.5/2.5/4 | 14/12 | PV-ES-CZM-18100 |
| Pos. | Cable cross section | suitable for |
| --- | --- | --- |
| mm2 | AWG | |
| 4 | 2.5 |
PV-KBT4/2.5…-UR
5| 4| 12| PV-KST4/6…-UR
PV-KBT4/6…-UR
6| 6| 10| PV-KST4/6…-UR
PV-KBT4/6…-UR
(ill. 3)
| Crimping range | Type | Order No. |
|---|---|---|
| mm2 | AWG | |
| 2.5/4/6 | 12/10 | PV-ES-CZM-19100 |
| Pos. | Cable cross section | suitable for |
| --- | --- | --- |
| mm2 | ||
| 7 | 4 | PV-KST4/6…-UR |
PV-KBT4/6…-UR
8| 10| PV-KST4/10…-UR
PV-KBT4/10…-UR
(ill. 4)
| Crimping range | Type | Order No. |
|---|---|---|
| mm2 | AWG |
4/10 PV-ES-CZM-20100
32.6021-20100
** Pos.| Cable cross section| suitable for
---|---|---
| mm2|
9**| 6| | PV-KST4/6…-UR
PV-KBT4/6…-UR
10| 10| | PV-KST4/10…-UR
PV-KBT4/10…-UR
(ill. 5)
| Crimping range | Type | Order No. |
|---|---|---|
| mm2 |
6/10 PV-ES-CZM-21100
32.6021-21100
Pos.| Cable cross section| suitable for
---|---|---
| AWG|
11| 8| PV-KST4/8II-UR PV-KBT4/8II-UR
12| 10| PV-KST4/6…-UR
PV-KBT4/6…-UR
13| 12| PV-KST4/6…-UR
PV-KBT4/6…-UR
(ill. 6)
| Crimping range | Type | Order No. |
|---|---|---|
| AWG |
8/12/10/ PV-CZM-22100 /32.6020-22100
| Pos. | Cable cross section | suitable for |
|---|---|---|
| AWG | ||
| 14 | 8 | PV-KST4/8II-UR PV-KBT4/8II-UR |
| 15 | 10/12 | PV-KST4/5…-UR |
PV-KBT4/5…-UR
16| 14| PV-KST4/5…-UR
PV-KBT4/5…-UR
(ill. 7)
| Crimping range | Type | Order No. |
|---|---|---|
| AWG |
8/10/12/14/ PV-CZM-23100/32.6021-23100
(ill. 8)
Locator PV-LOC Order No.: 32.6040
(ill. 9)
Locator PV-LOC-B Order No.: 32.6055
Note:
When using the crimping pliers PV-CZM-22100, use the locator PV-LOC-B.
(ill. 10)
Locator PV-LOC-D Order No.: 32.6074
Note:
When using the crimping pliers PV-CZM-23100, use the locator PV-LOC-D.
Explanation for MC4-Evo 2
(ill. 11)
Crimping pliers incline locator and built-in crimping diefi
Type| Conductor cross section| (B-Crimp) Open crimp contacts (B-Crimp)|
(O-Crimp) Closed crimp contacts (O-Crimp)| Crimping pliers| Crimping dies|
Locator
---|---|---|---|---|---|---
PV-CZM-40100 32.6020-40100
|
PV-CZM-41100 32.6020-41100
|
PV-CZM-42100 32.6020-42100
|
PV-ES-CZM-40100 32.6021-40100
|
PV-ES-CZM-41100 32.6021-41100
|
PV-ES-CZM-42100 32.6021-42100
|
PV-LOC-C 32.6056
PV-KST-EVO 2/2.5…-UR PV-KBT-EVO 2/2.5…-UR| 2.5 mm2| •| | •| •| | •| •| | •
14 AWG| •| | •| •| | •| •| | •
PV-KST-EVO 2/6…-UR,
PV-KBT-EVO 2/6…-UR
| 4 mm2| •| | •| •| •| •| •| •| •
12 AWG| •| | •| •| •| •| •| •| •
6 mm2| •| | •| •| | •| •| | •
10 AWG| •| | •| •| | •| •| | •
PV-KST-EVO 2/10…-UR, PV-KBT-EVO 2/10…-UR| 10 mm2| •| | | | •| | | •| •
8 AWG| •| | | | •| | | •| •
Pos.
| Cable cross section| suitable for
---|---|---
| mm2| AWG|
1| 1.5| | PV-KST4-EVO 2/2,5…-UR
PV-KBT4-EVO 2/2,5…-UR
2| 2.5| 14| PV-KST4-EVO 2/2,5…-UR
PV-KBT4-EVO 2/2,5…-UR
3| 4| 12| PV-KST4-EVO 2/6…-UR PV-KBT4-EVO 2/6…-UR
Individual parts
(ill. 12 + 13 + 14) Interchangeable crimping dies.
(ill. 12)
| Crimping range | Type | Order No. |
|---|---|---|
| mm2 | AWG | |
| 1.5/2.5/4 | 14/12 | PV-ES-CZM-40100 |
| Pos. | Cable cross section | suitable for |
| --- | --- | --- |
| mm2 | AWG | |
| 4 | 2.5 | 14 |
PV-KBT4-EVO 2/2,5…-UR
5| 4| 12| PV-KST4-EVO 2/6…-UR PV-KBT4-EVO 2/6…-UR
6| 6| 10| PV-KST4-EVO 2/6…-UR PV-KBT4-EVO 2/6…-UR
(ill. 13)
| Crimping range | Type | Order No. |
|---|---|---|
| mm2 | AWG | |
| 2.5/4/6 | 14/12/10 | PV-ES-CZM-41100 |
| Pos. | Cable cross section | suitable for |
| --- | --- | --- |
| mm2 | AWG | |
| 7 | 4 | 12 |
| 8 | 10 | 8 |
(ill. 14)
| Crimping range | Type | Order No. |
|---|---|---|
| mm2 | AWG | |
| 4/10 | 12/8 | PV-ES-CZM-42100 |
(ill. 15)
Locator PV-LOC-C Order no.: 32.6056
Exchanging the crimping die
(ill. 16)
Close the crimping pliers.
(ill. 17)
Remove completely both mounting screws: the long S and the short S1. Open the
crimping pliers (press completely together and release).
(ill. 18)
Remove the upper crimping die.
(ill. 19)
Remove the lower crimping die.
Fitting the crimping die (ill. 20)
- Open the crimping pliers (press completely together and release).
- Insert both crimping dies.
- The markings must be on the same side as the marking on the crimping pliers.
- Close crimping pliers and screw both crimping dies.
- But take care not to strip screw heads and to put each screw in its proper location.
(ill. 21)
Affix locator onto the guide pin.
(ill. 22)
Rotate the locator (held magnetically)
(ill. 23
Lock the locator.
Crimping
(ill. 24)
- Open clamp (K) and hold tight.
- Insert the contact in the appropriate cross-section range.
- Turn the crimping flaps (C) upwards.
- Release clamp (K).
- The contact is locked.
(ill. 25)
Verify if the crimping flaps are still correctly aligned.
Press the pliers gently together until the crimping flaps are properly located
with-in the crimping die.
(ill. 26)
Insert the stripped cable end until the cable strands come up against the
clamp.
Close the crimping pliers completely.
(ill. 27)
Visually check the crimp according to the criteria written in IEC 60352-2.
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.
- That the crimp is symmetrical in form.
- A “brush” of conductor strands are visible on the contact side of crimp.
Verify crimp height. Typical values for the crimp height for Stäubli PV cable Flex-Sol-Evo TX and Flex-Sol-Evo DX are listed below:
MC4| MC4-Evo 2| mm2| AWG| (B-Crimp) Open crimp contacts (B-Crimp)| (O-Crimp)
Closed crimp contacts (O-Crimp)| Cable| Crimp height
---|---|---|---|---|---|---|---
PV-KBT4/2,5…-UR| PV-KST4-EVO 2/2.5…-UR PV-KBT4-EVO 2/2.5…-UR
PV-KST4-EVO 2/6…-UR PV-KBT4-EVO 2/6…-UR
PV-KST4-EVO 2/6…-UR PV-KBT4-EVO 2/6…-UR
PV-KST4-EVO 2/10…-UR PV-KBT4-EVO 2/10…-UR
| 2.5
4.0
6.0
10
| 14
12
10
8
14
12
10
8
|
- Flex-Sol-Evo TX 2,5 Flex-Sol-Evo DX 2,5
- Flex-Sol-Evo TX 4,0 Flex-Sol-Evo DX 4,0
- Flex-Sol-Evo TX 6,0 Flex-Sol-Evo DX 6,0
- Flex-Sol-Evo TX 10 Flex-Sol-Evo DX 10
- Flex-Sol-Evo DX 2,5
- Flex-Sol-Evo DX 4,0
- Flex-Sol-Evo DX 6,0
- Flex-Sol-Evo DX 10
| 1.80
2.15
2.40
3.02
2.20
2.50
2.50
3.12
PV-KST4/2,5…-UR
PV-KBT4/6…-UR
PV-KST4/6…-UR
PV-KBT4/6…-UR
PV-KST4/6…-UR
PV-KBT/10…
PV-KST/10…
PV-KBT4/5…-UR
PV-KST4/5…-UR
PV-KBT4/5…-UR
PV-KST4/5…-UR
PV-KBT4/5…-UR
PV-KST4/5…-UR
PV-KBT4/8II-UR
PVKST4/8II-UR
Hersteller/Manufacturer: Stäubli Electrical Connectors AG Stockbrunnenrain 8
4123 Allschwil/Switzerland
Tel. +41 61 306 55 55
Fax +41 61 306 55 56
mail ec.ch@staubli.com
www.staubli.com/electrical
© by Stäubli Electrical Connectors AG, Switzerland – MA251 – 08.2022, Index d, Marketing Communications – Änderungen vorbehalten/Subject to alterations