ST UBLI MA231 Stripping Pliers 4/6/10 mm² Instruction Manual

ST UBLI MA231 Stripping Pliers 4/6/10 mm²

Male cable coupler

• PV-KST4/2.5…-UR
• PV-KST4/6…-UR
• PV-KST4/10…

• PV-KST4/5…-UR
• PV-KST4/8II-UR

• Optional
• PV-SSH4
• Sicherungshülse/Safety lock clip

(siehe/see www.staubli.com/electrical –> MA252)

Sealing caps

• PV-BVK4
• 32.0716
• PV-SVK4
• 32.0717

Safety instructions

Importance of the assembly instructions
NOT following the assembly and safety instructions could result in life- threatening injuries due to electric shock, electric arcs, fire, or failure of the system.

• Follow the entire assembly instructions.
• Use and install the product only according to this assembly instruction 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 photovoltaic array.
• The connector can be used for purposes other than those in a photovoltaic array, e.g., as an LVDC component. If the component is used for other purposes, then the requirements and specifications may be different from the ones described in this document.
• For more information, contact Stäubli at www.staubli.com/electrical.

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 the dangers that may originate from electricity. An electrician is 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 the dangers that may originate from electricity.

Prerequisites for installation and assembly

• NEVER use an obviously damaged product.
• ONLY tools and procedures 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 photovoltaic array or -string is de-energized.

Mating and disconnecting

• ALWAYS de-energize the photovoltaic system before mating and disconnecting the connectors.
• NEVER disconnect the connectors under load.
• NEVER connect the male or female part of the Stäubli connector with the connectors of other manufacturers.

Do NOT modify NOR repair component

• Mount the connector only once.
• Do NOT modify connectors after assembly.
• Replace defective connectors.

Tools required

• Stripping pliers PV-AZM…

Note
Operating instructions MA267,www.staubli.com/electrical.

• Assembly and unlocking tool
• PV-MS-PLS, Order No. 32.6058 or
• Open-end spanner set PV-MS,
• Order No. 32.6024

Note
Operating instructions MA270, www.staubli.com/electrical.

• Crimping pliers PV-CZM… incl. locator and crimping die.

Note
Operating instructions MA251, www.staubli.com/electrical.

Assign the crimping pliers to die and locator according to the connector chosen

Tab. 1

Type

| ****

Conductor cross-section

|  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-KBT4/2,5…-UR,

PV-KST4/2,5…-UR

| 2.5 mm2| •|  |  |  |
14 AWG| •|  |  |  |

PV-KBT4/6…-UR,

PV-KST4/6…-UR

| 4 mm2| •| •|  | •|
12 AWG| •| •|  | •|
6 mm2| •| •|  |  | •
10 AWG| •| •|  |  | •

PV-KBT4/5…-UR,

PV-KST4/5…-UR

| 14 AWG|  |  | •|  |
12 AWG|  |  | •|  |
10 AWG|  |  | •|  |
PV-KBT4/8II-UR, PV-KST4/8II-UR| 8 AWG|  | •| •|  |
PV-KBT4/10II, PV-KST4/10II| 10 mm2|  |  |  | •| •
 |  | Note:

For crimping die and locator information, please see the operating instructions MA251, www.staubli.com/electrical

• PV-WZ-Torque-Set,  Order No. 32.0065
• Test plug PV-PST Order No. 32.6028
• Open-end spanner wrench 15 mm
• Torque wrench 12 mm (1/2” drive)
• Cable cutter PV-WZ-KS, Order No. 32.6080

Note
Operating instructions MA705, www.staubli.com/electrical.

Notes on connectors and components storage

Stäubli recommends storing connector components at a preferably constant temperature range between –30°C and +60°C and relative humidity of less than 70%.  The components must not be exposed to moisture due to direct rainfall, condensation, etc. Ensure that individual components do not get into contact with acids, alkalis, gases, acetone or any other aggressive chemical substances, which might impact the material’s performance. Once all these storage conditions are met the components could be stored up to two years behind manufacturing.

Guideline for connector configuration

Note
Please use the smaller sealing if the cable diameter used is between two limits.

Cable preparation

For IEC applications cables with flexible conductors of class 5 or 6 according to IEC 60228 shall be connected. For the UL-approved range applications power cables of class B or higher shall be connected.

Attention

• Used tinned copper conductors. Do not use uncoated (bare*) nor already oxidized conductors. All Staubli solar cables have high-quality, tinned conductors. For safety reasons, Stäubli prohibits the use of PVC cables and the use of non-tinned cables of type H07RN-F.
• It is acceptable to use bare copper conductors, class B or higher with the following products: PV-KBT4/5…-UR, PV-KST4/5…- UR, PV-KBT4/8II-UR and PV-KST4/8II-UR

Check dimensions A and b, see Tab. 2 on page 5 and tab. 3 on page 6.

Note
In case other diameters than those mentioned in Tab. 2 and Tab. 3 are used contact Stäubli.

Choose a connector configuration verified by TÜVRheinland

Cables connected to the connector shall be suitable for use in photovoltaic systems and shall comply with the requirements of IEC 62930.

Tab. 2

A: ø range of the cable [mm]

|  Conductor cross-section
---|---
2.5 mm2| 4 mm2| 6 mm2| 10 mm2
5.0 – 6.0| PV-KxT4/2,5I-UR| PV-KxT4/6I-UR| PV-KxT4/6I-UR| PV-KxT4/10I
5.5 – 7.4| PV-KxT4/2,5X-UR| PV-KxT4/6X-UR| PV-KxT4/6X-UR| PV-KxT4/10X
7.0 – 8.8| PV-KxT4/2,5II-UR| PV-KxT4/6II-UR| PV-KxT4/6II-UR| PV-KxT4/10II

b: control dimension

| ~4 mm| ~5.8 mm| ~6.5 mm

Note

• The following topic needs to be considered when selecting the PV cable:
• The sheath material of the PV cable has to meet insulation class 1 according to IEC 60664-1.

Selection of connector configuration when using cables certified at UL

Cables connected to the connectors shall be suitable for use in photovoltaic systems and shall comply with the requirements of ZKLA (PV-wire) or TYLZ (USE-2).

Tab. 3

|

Conductor cross-section AWG (stranding)

---|---
A: ø-Bereich der Leitung [mm] A: ø range of the cable [mm]
ZKLA (PV-wire)| TYLZ (USE-2)| 14| 12| 10| 8
600/1000/1500| 600| 19-49| 7-49| 7-65 | 7-65| 7-78 | 7-78| 7-168
5.60 – 6.20| 4.80 – 6.20| PV-KxT4/2,5I-UR| PV-KxT4/5I-UR| PV-KxT4/6I-UR| PV- KxT4/5I-UR| PV-KxT4/6I-UR| PV-KxT4/5I-UR|
6.20 – 7.00| 6.20 – 7.00| PV-KxT4/2,5X-UR| PV-KxT4/5X-UR| PV-KxT4/6X-UR| PV- KxT4/5X-UR| PV-KxT4/6X-UR| PV-KxT4/5X-UR|
7.00 – 8.60| 7.00 – 8.60| PV-KxT4/2,5II-UR| PV-KxT4/5II-UR| PV-KxT4/6II-UR| PV-KxT4/5II-UR| PV-KxT4/6II-UR| PV-KxT4/5II-UR|
5.95 – 8.00| 8.30 – 8.56|  |  |  |  |  |  | PV-KxT4/8II-UR

b: control dimension

| 4 mm| ~3 mm| 5.8 mm| ~3 mm| 5.8 mm          ~3 mm| ~4.4 mm

preferred conductor stranding: 19-65

Note
If your chosen cable is suitable for both configurations listed in Tab. 2 and 3 as well as in the technical data on page 12, it can be used as a double- certified cable according to TÜV Rheinland and UL.

• Strip cable insulation (length L) according to ranges mentioned in Tab. 4 and check.

Attention

• Do not cut single strands when stripping the cable!

Tab. 4

Crimping

For crimping open crimp contacts (B-Crimp) PV-KxT4/2.5…-UR; PV-KxT4/6…-UR or PV-KxT4/10…

• 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.

For crimping closed crimp contacts (O-Crimp) PV-KxT4/5…-UR or PV-KxT4/8II- UR

• Place the contact in the appropriate cross-section range.

• For PV-KxT4/5… and PV-KxT4/8…:

• Place contact into the appropriate

• locator position, based on the conductor cross-section to be crimped.

• Make sure the contact is fully inserted into the locator before crimping.

• Press the pliers gently together until the crimping flaps are properly located within the crimping die.

• Insert the stripped cable end until the lead strands come up against the clamp.

• Completely close the crimping pliers.

• 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
• the crimp is symmetrical
• a “brush” of conductor strands is visible on the contact side of the crimp.

Assembly check

• Insert the crimped contact into the insulator of the male or female coupler until engaged. You will typically hear a “click” sound once fully engaged. Pull gently the cable to verify that the metal part is correctly engaged.

• Insert the appropriate end of the test pin into the male or female coupler as far as it will go. If the contact is assembled properly the white mark on the test pin must still be visible.

• Pre-tighten the cable gland with tools PV-MS or PV-MS-PLS. tighten cable gland using the

• PV-WZ-Torque-Set while supporting the insulator front with PV-MS or PV-MS-PLS.

• The tightening torque must be appropriate
  for the solar cables used. Typical values are between 3.4 N m and 3.5 N m1).

• Stäubli recommends using a calibrated torque wrench for assembly. The NFPA National Electric Code (NEC 2017) requires the use of a calibrated torque wrench in section 110.14(D).

Note
For assembly of components, an ambient temperature between -15 °C and +35 °C is recommended.

Note
Do not bottom out the cap nut.

Mating and disconnecting the cable coupler without safety lock clip PV-

SSH4

Mating

• Mate the cable coupler until a „Click“ can be heard. Check correct engagement by lightly pulling on the connector (maximum pulling force: 20 N).

Attention

• Assembly of not fully engaged connectors is not permitted as this could lead to a permanent deflection of clips and thus to a potential loss of the locking function.
• The assembly has to be verified in any case.

Disconnecting

• Push the unlocking pins of PV-MS or PV-MS-PLS onto the locking clips (X) of the socket and separate the coupling.

Mating and disconnecting the cable coupler once the safety lock clip PV- SSH4 is involved

Mating

• Mate the cable coupler until a „Click“ can be heard. Check correct engagement by lightly pulling on the connector (maximum pulling force: 20 N).

Disconnecting

Push the unlocking pins of PV-MS or PV-MS-PLS into the openings provided in PV-SSH4 and onto the locking clips of the socket and separate the coupling.

Notes on installation

Note
If the connector is to be used in low-voltage DC applications other than those in a photovoltaic array, please consult the information as provided in the Stäubli Technical Description Report. Link.

General notes on installation

• Unmated connectors must be protected from environmental impact (moisture, dirt, dust, etc.) with 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.

Cable routing
Cable management must allow a minimum of 20 mm of cable that exits directly from the cable seal without bending or stress. Refer to the cable manufacturers specification for minimum bending radius.

Contaminated/damaged connectors

• Do not allow connectors to be contaminated by the environment (e.g. soil, water, insects, dust).
• Do not allow the connector to be contaminated on its surface (e.g. stickers, paint, heat shrink tubing).
• Do not allow the connector is directly on the roofing surface.
• Do not allow the connector is at the lowest point of the cabling where water can collect.
• Do not allow the connector is in standing water.
• Do not allow that cable ties to be mounted directly on the connector body.

Mechanical stress

• Check that the connectors are not subjected to a permanent mechanical tensile load or vibration.
• Connectors shall not be under strain from cable management.

Technical data

Rated voltage:

IEC 62852:2014 + Amd1:2020 2 PfG 2330/04.2013

UL 6703

| ****

DC 1000 V 1)

DC 1500 V 1), 2)

DC 1500 V 3)

Rated current IEC (85 °C)

| 22,5 A (2,5 mm²)

39 A (4 mm²/6 mm²)

45 A (10 mm 2 )

Rated current (UL)

| 30 A (14 AWG) 4)

35 A (12 AWG) 4)

50 A (10 AWG) 4)

70 A (8 AWG) 4)

Rated impulse voltage| 12 kV (DC 1000 V)

16 kV (DC 1500 V)

Ambient temperature range| -40 °C…+85 °C (IEC)

-40 °C…+85 °C (UL)

Transportation/storage temperature range| -30 °C/+60 °C
Transportation/storage relative humidity| < 70 %
Upper limiting temperature| 105 °C (IEC)
MOT max. operating temperature| +85 °C 4)
Degree of protection mated

unmated

| IP65/IP68 (1 m, 1 h)

IP2X

Overvoltage category/Pollution degree| CAT III/3
The contact resistance of plug connectors| 0.25 mΩ
The polarity of the connectors| Buchse/Socket = Plus/positive

Stecker/Plug  = Minus/negative

Locking system| Locking type
Safety class (IEC)| II: DC 1000 V

0: DC 1500 V

Contact system| MULTICAM
Type of termination| Crimpen/Crimping
Safety instruction| Nicht unter Last trennen

Do not disconnect under load

Contact material| Kupfer, verzinnt/Copper, tin plated
Insulation material| PC/PA
Flame class| UL94-V0
Salt mist spray test, degree of severity 6| IEC 60068-2-52
Ammonia resistance (according to DLG)| 6076F (1500 h, 70 °C/70 % RH, 750 ppm)
TÜV-Rheinland certified according to IEC 62852:2014 + Amd.1:2020| R 60127190
TÜV-Rheinland certified according to 2 PfG 2330/04.2013| R 60087448
UL certified according to UL 6703| E343181
CSA certified according to UL 6703| 250725
JET certified according to IEC 62852:2014| 1625-C43O4-302
CQC certified| 2013003030Z
Max. operating altitude above sea level according to IEC 62852:2014 + Amd.1:2020| 5000 m; AK 60159411
Temperature Level according to IEC TS 63126:2020| Level 2; AK 60158515

1. Cables connected to the connector shall be suitable for use in photovoltaic systems and shall comply with the requirements of IEC 62930.
2. IEC DC 1500 V: Only for use in PV systems in access-restricted areas.
3. For applicable cable diameter please see table 3 in this assembly instructions.
4. Engineering considerations: Application-associated current ratings have to be verified in the product’s end-use and shall not exceed the maximum operating temperature.

Manufacturer

• 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.

References

• Electrical connectors for reliable, safe and durable solutions - Stäubli

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