ST UBLI MC4-Evo Stor Connector Instruction Manual

ST UBLI MC4-Evo Stor Connector Instruction Manual

Module

• PV-KBT4-EVO ST
  

• PV-KST4-EVO ST
  
  

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, 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 MC4-Evo stor connector electrically connects the DC side of an inverter and the BESS (battery energy storage system)
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 specifi cations may be diff erent 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

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… including built-in stripping blades and Allen key 2.5 mm

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

(ill. 2)

Crimping pliers PV-CZM… and locator.

32.6084
4/10/6 mm2 (12/8/10 AWG)| PV-CZM-60100 32.6020-60100| PV-LOC-MC4-EVO 2 32.6083

Note:
Operating instructions MA704,
www.staubli.com/electrical

(ill. 3)

Assembly and unlocking tool PV-MS-PLS, Order No. 32.6058

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

(ill. 4)

PV-WZ-Torque-Set, Order No. 32.0065 or Torque wrench 17 mm

(ill. 5)

Test plug PV-EVO-PST, Order No. 32.6073

(ill. 6)

Cable cutter PV-WZ-KS, Order No. 32.6080

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

Cable reparation

(ill. 7)

Cables with a strand class 5 and 6 shall be connected. Use tinned copper cables only

Attention
Do not use oxidized nor bare (i.e. uncoated) conductors. All Stäubli solar cables have high grade tinned conductors. For safety reasons, Stäubli prohibits the use of PVC cables and the use of non-tinned cables of type H07RN-F.

Check dimensions A and b in accordance with ill. 6 and Tab. 1 and 2. Proper selection of the appropriate configuration:

Cable reparation

(ill. 7)
Cables with a strand class 5 and 6 shall be connected. Use tinned copper cables only.

Attention
Do not use oxidized nor bare (i.e. uncoated) conductors. All Stäubli solar cables have high grade tinned conductors. For safety reasons, Stäubli prohibits the use of PVC cables and the use of non-tinned cables of type H07RN-F.

Check dimensions A and b in accordance with ill. 6 and Tab. 1 and 2. Proper selection of the appropriate configuration:

Note:
The usable seals can be easily distinguished by the color:

Guideline for configuring the connectors

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

1. MC4-Evo ST product configuration in combination with TUV Rheinland, TUV Rheinland/UL and cTUVus

Choose the suitable configuration in Tab. 1 by using TÜV Rheinland, TÜV Rheinland/UL (dual) or cTÜVus certified cables1),2):

Type

PV-K..T4-EVO ST/2.5X: PV-K..T4-EVO ST/2.5II
PV-K..T4-EVO ST/6X: PV-K..T4-EVO ST/6I
PV-K..T4-EVO ST/10X: PV-K..T4-EVO ST/10II
5.9 – 7.3: 6.4 – 8.4

1. Cables connected to the connector shall be suitable for use in photovoltaic systems and shall comply with the requirements of IEC 62390.
2. For an end use of the product in systems > DC 1000 V, the following points must be considered when selecting the PV cable:
   • The PV cable has to meet conductor class 5 according to IEC 60228:2005
   • The sheath material of the PV cable has to meet insulation class 1 according to IEC 60664-1.

MC4-Evo ST Product configuration in combination with UL

(ill. 8)
Strip cable to dimension 6.0 to 7.5 mm.

  Attention
Do not cut individual strands when stripping!

Crimping

(ill. 9)

• 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:
Make sure that the contact is placed in the housing and is held by the clamp.

(ill. 10)
Verify if the crimping flaps are still correctly aligned.

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

(ill. 11)
Insert the stripped lead end until the lead strands come up against the locator.
Completely close the crimping pliers.

(ill 12)
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. 13)
Insert the crimped-on contact into the insulator of the male or female coupler until engaged.
You will typically hear a “click” sound once fully inserted.
Pull gently on the lead to check that the metal part is correctly engaged.

(ill. 14)
Insert the appropriate end of the test pin into the male or female coupler as far as it will go.
If the contact is correctly located, the white mark on the test pin must still be visible.

(ill. 15)

• Pre-tighten cable gland with tool PV-MS-PLS.
• Tighten cable gland using PV-WZ-Torque-Set while supporting the insulator front with the PV-MS-PLS.

Note:
The acting tightening torque must be adapted to the solar cables used in each specific case. See Tab 3.

Note:
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 per section 110.14(D).

Mating and disconnecting

(ill. 16)
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 correct assembly has to be verified at all times.

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

(ill. 17)
Disconnecting:
Use PV-MS-PLS/2 to disconnect.

Notes on installation

General notes on installation

• Unmated connectors must be protected from environmental impact (moisture, dirt, dust, etc.) with sealing caps (socket PV-BVK4, order No. 32.0716; plug PV-SVK4, order No. 32.0717).
• Do not mate contaminated connectors.
• Connectors must not come into contact with any chemicals.
• The design of the short-circuit resistance of the entire system must not exceed the short-circuit resistance of the connector. Short-circuit resistance of connectors to be clarified with Stäubli.

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

62 A (10.0 mm²)
Rated current (UL)| 30 A (14 AWG) 39 A (12 AWG) 50 A (10 AWG) 70 A (8 AWG)
Rated impulse voltage| 16 kV (DC 1500 V)
Ambient temperature range| -40 °C … +85 °C (IEC/UL)
Upper limiting temperature| 115 °C (IEC)
Degree of protection, mated| IP65/IP68 (1 m, 1 h)
Degree of protection, unmated| IP2x
Overvoltage category/Pollution degree| CAT III/3
Contact resistance of plug connectors| < 0.2 mΩ
Polarity of connectors| Buchse/Socket = Plus/positive Stecker/Plug = Minus/negative
Locking system| Locking type
Safety class (IEC)| II
Contact system| MULTILAM
Type of termination| Crimpen/crimping
Warning| Nicht unter Last trennen Do not disconnect under load
Contact material| Kupfer verzinnt, copper, tin plated
Insulation material| PA
Flame class| UL94-V0
Compatible with| MC4-Evo stor (PV-ADB4-EVO ST/x, PV-ADS4-EVO ST/x)
TÜV-Rheinland certified according to IEC 62852:2014+Amd.1:2020| R 60163331
UL certified according to UL 6703| E343181

Hersteller/Manufacturer:
Stäubli Electrical Connectors AG
Stockbrunnenrain 8 4123 Allschwil/Switzerland

Tel. +41 61 306 55 55
Fax +41 61 306 55 56
mail [email protected]
www.staubli.com/electrical
12/12

© by Stäubli Electrical Connectors AG, Switzerland – MA297 – 09.2022, index a Marketing Communications – Änderungen vorbehalten / Subject to alterations

Read User Manual Online (PDF format)

Download This Manual (PDF format)

Download this manual  >>