STAUBLI PV-CZM-19100 Electrical Connectors Crimping Tool Instruction Manual
- June 13, 2024
- STAUBLI
Table of Contents
4866N85000
MA251 (de_en)
Operating instructions
Crimping pliers PV-CZM
Care instructions
To ensure best crimp performance and crimping pliers service life the following care instructions shall be met:
- Clean the crimping pliers from dust, moisture and other residues using a clean, soft brush or lint-free cloth.
- Do not use any harsh or abrasive agents.
- Regular visual inspection of the profile area regarding damage or wear.
- When crimping pliers are not in use, store them in a clean and dry place.
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, fire, 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:
Intended use
The present hand tools are in place to deliver crimp excellence for Stäubli PV
connectors with cables. Crimpings shall be carried out only in de-energized
state of the cables.
The hand tool is NOT suitable for Live working (IEC 60900)
Crimping pliers emergency opening
Required tool for emergency opening: Screwdriver with fine tip e.g 3 × 75 mm
Goal: crimping pliers emergency opening.
Action step:
- Turn the screw with the screwdriver (clockwise/counterclockwise).
Result:
- The locking mechanism loosens.
Note:
Once the crimping pliers have been opened using the emergency opening, the
metal crimp in process needs to be discarded.
Note:
No special action necessary to use the crimping pliers for any next crimp
operation following an emergency opening.
Crimping pliers equipped for MC4 connectors
Individual parts
(ill. 2 + 3 + 4 + 5 + 6 + 7)
Interchangeable crimping dies.
(ill. 2)
| Type | Order No. |
|---|---|
| PV-ES-CZM-18100 | 32.6021-18100 |
(ill. 3)
| Crimping range | Type | Order No. |
|---|---|---|
| mm2 | AWG | |
| 1.5/2.5/4 | 14/12 | PV-ES-CZM-18100 |
(ill. 4)
| Crimping range | Type | Order No. |
|---|---|---|
| mm2 | AWG | |
| 10-Apr | PV-ES-CZM-20100 |
(ill. 5)
| Crimping range | Type | Order No. |
|---|---|---|
| mm2 | ||
| 10-Jun | PV-ES-CZM-21100 |
(ill. 6)
Locator PV-LOC
Order No: 32.6040
(ill. 7)
| Crimping range | Type | Order No. |
|---|---|---|
| AWG | ||
| 8/12/2010 | PV-CZM-22100 | 32.6020-22100 |
(ill. 8)
Locator PV-LOC-B
Order No: 32.6055
Note:
When using the crimping pliers
PV-CZM-22100, use the locator
PV-LOC-B
(ill. 9)
| Crimping range | Type | Order No. |
|---|---|---|
| AWG | ||
| 8/10/12/14 | PV-CZM-23100 | 32.6021-23100 |
(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.
Crimping pliers equipped for MC4-EVO 2 connectors
(ill. 11)
Crimping pliers incl. locator and built-in crimping die.
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 |
(ill. 13)
| Crimping range | Type | Order No. |
|---|---|---|
| mm2 | AWG | |
| 2.5/4/6 | 14/12/10 | PV-ES-CZM-41100 |
(ill. 14)
| Crimping range | Type | Order No. |
|---|---|---|
| mm2 | AWG | |
| 10-Apr | 8-Dec | PV-ES-CZM-42100 |
(ill. 15)
Locator PV-LOC-C
Order no: 32.6056
Exchanging the crimping die
Removing 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 within 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)
After crimping,
- move the locator to default position
- remove contact (see arrow in ill 15 for interaction to achieve default position of locator)
Note:
The crimp terminals shall not be released from the crimping pliers under
force. They should come out easily
(ill. 28)
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:
Good crimp
Bad crimp:
- Stamped parts bent wrongly
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
Read User Manual Online (PDF format)
Read User Manual Online (PDF format) >>