STAUBLI MA231 PV Male Cable Coupler Instruction Manual

STAUBLI MA231 PV Male Cable Coupler

Product Information

This product is a PV-Kupplungsstecker PV-KST4/…-UR (PV male cable coupler) and PV-Kupplungsbuchse PV-KBT4/…-UR (PV female cable coupler). It is designed to electrically connect components within the DC circuits of a photovoltaic array. The connectors can also be used for other purposes, such as LVDC components, but the requirements and specifications may vary.

It is important to follow the assembly and safety instructions provided in the manual to prevent life-threatening injuries due to electric shock, electric arcs, fire, or system failure.

Only an electrician or electrically instructed person should assemble, install, and commission the system.

Product Usage Instructions

1. Ensure safe assembly and mounting. Live parts can remain energized after isolation or disconnection.
2. Use the specified tools for installation and assembly:
   • Abisolierzange PV-AZM… (Stripping pliers PV-AZM…) – Refer to illustration 1 for details.
   • Montage- und Entriegelungswerkzeug PV-MS-PLS (Assembly and unlocking tool PV-MS-PLS) – Refer to illustration 2 for details.
   • Crimpzangen PV-CZM-6×100 inkl. Lokator und Crimpeinsatz (Crimping pliers PV-CZM-6×100 including locator and crimping die) – Refer to illustration 3 for details.
   • Crimpzangen PV-CZM-2×100 inkl. Lokator und Crimpeinsatz (Crimping pliers PV-CZM-2×100 including locator and crimping die) – Refer to illustration 4 for details.
3. Assign the appropriate crimping pliers die and locator according to the chosen connector. Refer to Table 1 for details.
4. Do not modify or repair the component.

For more detailed instructions and information, refer to the respective operating instructions mentioned in the manual.

Female cable coupler Male cable coupler

see www.staubli.com/re-downloads.html –> MA252

Sealing caps

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, fi re, or failure of the system.

• Follow the entire assembly instructions.
• Use and install the product only according to this 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 photovoltaic array.
The connector can be used for purposes other than those in a photovoltaic array, e.g., as a 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 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 male or female part of Stäubli connector with connectors of other manufacturers.
• NEVER mate contaminated connectors.

Do NOT modify NOR repair component

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

| Tools required|
---|---|---
| (ill. 1)
Stripping pliers PV-AZM…
|
Conductor cross section| Type| Order No.
mm2| AWG| |
1.5/2.5/4/6| –| PV-AZM-156| 32.6027-156
4/6/10| –| PV-AZM-410| 32.6027-410
| | |
Note
Operating instructions MA267, www.staubli.com/re- downloads.html|
(ill. 2)
Assembly and unlocking toolPV-MS-PLS, Order No. 32.6058
or
Open-end spanner set PV-MS, Order No. 32.6024|
Note
Operating instructions MA270, www.staubli.com/re- downloads.html|
(ill. 3)
Crimping pliers PV-CZM-6×100 incl. locator and crimping die.|
Note
Operating instructions MA704, www.staubli.com/re- downloads.html|
(ill. 4)
Crimping pliers PV-CZM-2×100 incl. locator and crimping die.|
Note
Operating instructions MA251, www.staubli.com/re- downloads.html|

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

Tab. 1

Type| Conductor cross section| Open crimp contacts B-Crimp| Closed crimp contacts

O-Crimp

| Crimping pliers
---|---|---|---|---
PV-CZM-61100 32.6020-61100| PV-CZM-60100 32.6020-60100| PV-CZM-23100 32.6020-23100| PV-CZM-22100 32.6020-22100
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 open crimps, related crimping die and locator information, please see the operating instructions MA704, www.staubli.com/electrical

• The harmonized crimping pliers shall not be used along with 0-crimps (PV-KST4/5…; PV-KBT4/5…; PV-KST4/8…; PV-KBT4/8…).
  See operating instructions in MA251 regarding assembly of closed crimps (O-crimps) including dedicated inserts and locators.

(ill. 5)
PV-WZ-Torque-Set, Order No. 32.0065

(ill. 6)
Test plug PV-PST Order No. 32.6028

(ill. 7)
Cable cutter PV-WZ-KS Order No. 32.6080

Notes on connectors and components storage
Stäubli recommends to store connector components at a prefer-ably 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 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 ap-proved 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 rea-sons, 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

(ill. 8)
Check dimensions A and b, see Tab. 2 on page 6 and tab. 3 on page 7.

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

Choose connector configuration verified by TÜV- Rheinland
Cables connected to the connectors shall be suitable for use in photovoltaic systems and shall comply with the requirements of IEC 62930.

Tab. 2

Note
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

Type of cable| TYLZ (USE-2)|
---|---|---
Rated voltage [V] DC| 600
Open crimp contacts| | Closed crimp contacts
A: Outer Ø PV wire [mm]| AWG14| AWG12| AWG10| AWG14| AWG12| AWG10| AWG8
4.80 – 6.20| PV-KxT4/2,5I-UR| PV-KxT4/6I-UR| PV-KxT4/6I-UR| | PV-KxT4/5I-UR| PV-KxT4/5I-UR| PV-KxT4/5I-UR|
6.20 – 7.00| PV-KxT4/2,5X-UR| PV-KxT4/6X-UR| PV-KxT4/6X-UR| PV-KxT4/5X-UR| PV- KxT4/5X-UR| PV-KxT4/5X-UR|
7.00 – 8.60| PV-KxT4/2,5II-UR| PV-KxT4/6II-UR| PV-KxT4/6II-UR| PV-KxT4/5II-UR| PV-KxT4/5II-UR| PV-KxT4/5II-UR|
8.30 – 8.56| | | | | | | PV-KxT4/8II-UR
Quantity of stranding| 19 – 49| 7 – 65 | 7 – 78 | | 7 – 49| 7– 65| 7 – 37| 7 – 168
b: control dimension [mm]|

4

|

5.8

|

5.8

|

~3

|

~3

|

~3

|

~4.4

Type of cable| ZKLA (PV-wire)|
---|---|---
Rated voltage [V] DC| 600/1000/1500
Open crimp contacts| | Closed crimp contacts
A: Outer Ø PV wire [mm]| AWG14| AWG12| AWG10| AWG14| AWG12| AWG10| AWG8
5.60 – 6.20| PV-KxT4/2,5I-UR| PV-KxT4/6I-UR| PV-KxT4/6I-UR| | PV-KxT4/5I-UR| PV-KxT4/5I-UR| PV-KxT4/5I-UR|
6.20 – 7.00| PV-KxT4/2,5X-UR| PV-KxT4/6X-UR| PV-KxT4/6X-UR| PV-KxT4/5X-UR| PV- KxT4/5X-UR| PV-KxT4/5X-UR|
7.00 – 8.60| PV-KxT4/2,5II-UR| PV-KxT4/6II-UR| PV-KxT4/6II-UR| PV-KxT4/5II-UR| PV-KxT4/5II-UR| PV-KxT4/5II-UR|
6.00 – 8.80| | | | | | | PV-KxT4/8II-UR
Quantity of stranding| 19 – 49| 7 – 65 | 7 – 78 | | 7 – 49| 7– 65| 7 – 37| 7 – 168
b: control dimension [mm]|

4

|

5.8

|

5.8

|

~3

|

~3

|

~3

|

~4.4

• 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 13, it can be used as a double certified cable according TÜV Rheinland and UL.

(ill. 9)
Strip cable insulation (length L) according to ranges mentioned in Tab. 4 and check.

Attention
Do not cut strands when stripping the cable!

Tab. 4

Crimping (ill. 10)
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.

Note
Operating instructions MA704, www.staubli.com/re- downloads.html

(ill. 11)
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 conductor cross-section to be crimped.

.

Note
Operating instructions MA251, www.staubli.com/re- downloads.html

(ill. 12)
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.

(ill. 13)
Attention
The distance x between the crimped contact and the wire insulation must be maintained.

(ill. 14)
Insert the stripped cable end until the lead strands come up against the clamp.
Completely close the crimping pliers.

(ill. 15)
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
• A “brush” of conductor strands are visible on the contact side of crimp.

Assembly check

(ill. 16)
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.

(ill. 17)
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.

Cable gland assembly (ill. 18)

• Pre-tighten cable gland with tools PV-MS or PV-MS-PLS.
• Tighten cable gland using the PV-WZ-Torque-Set while holding up 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).

1. Stäubli recommends to use 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 capnut.

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

SSH4

Mating
(ill. 19)
Mate the cable coupler until a „Click“ can be heard. Check correct engagement by lightly pulling on the connector (pulling force: max. 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 correct mating has to be verified.

Disconnecting
(ill. 20)
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 safety lock clip PV-SSH4 is involved

Mating
(ill. 21)
Mate the cable coupler until a „Click“ can be heard. Check correct engagement by lightly pulling on the connector (pulling force: max. 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 and wire management

• Cable management must allow a minimum of 20 mm of cable that exits directly from the cable seal without bending or stress.
• Do not allow that the connector is at the lowest point of cabling where water can collect.

Refer to 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 that the connector is directly on the roofing sur-face.
• Do not allow that the connector is in standing water.
• Do not allow 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

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 (ULT)| 105 °C (IEC)
Max. operating temperature (MOT)| +85 °C 4)
Degree of protection, mated unmated| IP65/IP68 (1 m, 1 h)

IP2X

Overvoltage category/Pollution degree| CAT III/3
Contact resistance of plug connectors| 0.25 mΩ
Polarity of the connectors| Stecker/Plug  = Minus/negative
Locking system| Locking type
Safety class (IEC)| II: DC 1000 V

0: DC 1500 V

Contact system| MULTILAM
Type of termination| Crimping
Safety instruction| Do not disconnect under load
Contact material| 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 accor- ding 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. 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 products end-use and shall not exceed the maximum operating temperature.

© by Stäubli Electrical Connectors AG, Switzerland – MA231 – 03.2023 – index g Marketing Communications Subject to alterations

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

References

• Electrical connectors for reliable, safe and durable solutions - Stäubli
• RE Downloads
• Downloads, Dokumentation und 3D CAD-Datenbank - Stäubli Electrical Connectors
• Electrical connectors for reliable, safe and durable solutions - Stäubli
• Downloads, documentation and 3D CAD library - Stäubli Electrical Connectors

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