STAUBLI MA251 Crimping Pliers Instruction Manual

MA251 Crimping Pliers

MA251 (de_en)

Operating instructions
Crimping pliers PV-CZM-…

Conductor cross sections:
4 mm², 6 mm², 10 mm²

PV-CZM-60100
32.6020-60100

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/re-downloads.html

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.

Product overview

Crimping pliers with interchangeable crimping dies and locators.

MC4 konnektörler

MC4 connectors

32.6082

PV-CZM-61100

32.6020-61100

2.5 mm²; 4 mm²; 6 mm²

PV-CZM-60100

32.6020-60100

4 mm²; 6 mm²; 10 mm²

32.6021-61100

MC4-Evo 2 konnektörler

MC4-Evo 2 connectors

32.6084

MC4 konnektörler

MC4 connectors

32.6081

32.6021-60100

MC4-Evo 2 konnektörler

MC4-Evo 2 connectors

32.6083

Individual parts

(ill. 1)
Interchangeable crimping die for cable
cross sections 4 mm², 6 mm² and

Sıkma aralığı
Crimping range
AWG
Tip
Type
Sipariş No.
Order No.
12; 10; 8* PV-ES-CZM-60100 32.06021-60100

• 8 AWG (10 mm²) MC4 makara kıvrımlarının kıvrılması, konektörler için ilgili UL dosyasında listelenmemiştir.
  Crimping of 8 AWG (10 mm²) MC4 barrel crimps is not listed in the related connector UL file.

Note:
The crimping pliers are not
designed for to be used along with
crimping terminals PV-KST4/5…;
PV-KBT4/5…; PV-KST4/8…;
PV-KBT4/8…; PV-KBT4/13…;
PV-KST4/13…
See table on page 4.

(ill. 2)
Locators:
MC4 connectors:
PV-LOC-MC4
Order No. 32.6081
MC4-Evo 2 connectors:
PV-LOC-MC4-EVO 2
Order No. 32.6083

Note:
The locators with black metal body
must be used only for MC4 crimp terminals.
The locators with grey metal
body must be used only for
MC4-Evo 2 crimp terminals

ill. 4)
Locators:
MC4 connectors:
PV-LOC-MC4
Order No. 32.6082

MC4-Evo 2 connectors:
PV-LOC-MC4-EVO 2
Order No. 32.6084

Note:
The locators with black metal body
must be used only for MC4 crimp
terminals. The locators with grey
metal body must be used only for
MC4- EVO 2 crimp terminals.

Exchanging the crimping die

Removing the crimping die

(ill. 5)
• Close the crimping pliers and hold it
closed.
• Unlock the locator (if still mounted);
• pull it upwards out of the crimping
pliers.

(ill. 6)
• Completely unscrew screw S (long)
and S1 (short) completely using an
Allen key 2.5 mm (not included in
scope of delivery).
• Open the crimping pliers.

(ill. 7)
• Remove the upper crimping die.

(ill. 8)
• Remove the lower crimping die.

Fitting the crimping die

(ill. 9)
The crimping dies can be inserted only
when the handles are open. Insert the
dies separately. The laser identification
of the dies needs to face towards the
operator as well as the crimping pliers
identification.

Note:
When inserting the dies make sure
that the anvil (lower die) is inserted
first, only then insert the punch.

• Close the crimping pliers.
• Place the screws in the correct position.
Do not damage the screw
heads.

(ill. 10)
• Screw in screw S (long) and S1 (short)
completely.

Note:
The pictures describe the locator for MC4-Evo 2 crimps. The
assembly of the locator for MC4 is comparable.

(ill. 11)
1. Affix locator onto the guide pin.
2. Rotate the locator (held magnetically).
3. Lock the locator.

Crimping

(ill. 12)
• 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. 13)
• Verify if the crimping flaps are still
correctly aligned.

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

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

Note:
Observe the stripping length of the
PV cable supplier.
Do not damage strands when stripping
the cable!

(ill. 15)
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.

Verify the crimped assembly

(ill. 16)
Visually check the crimp according to criteria listed 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 shape
• 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:

WZ 1 *61100  MC4-Evo 2

Conductor cross
section
mm²| Coding| Conductor cross
section
AWG| Crimp height
± 0.05 mm| Crimp width
± 0.1 mm| Contact type| Order No.
---|---|---|---|---|---|---
2.5| A1| 14| 1.8| 3.11| PV-SP4-EVO 2/2,5
PV-BP4-EVO 2/2,5| 32.0520P
32.0120P
4| B1| 12| 2.15| 4.2| PV-SP4-EVO 2/6
PV-BP4-EVO 2/6| 32.0521P
32.0121P
6| C1| 10| 2.4| 4.28| PV-SP4-EVO 2/6
PV-BP4-EVO 2/6| 32.0521P
32.0121P*

Conductor cross
section
mm²| Coding| Conductor cross
section
AWG| Crimp height
± 0.05 mm| Crimp width
± 0.1 mm| Contact type| Order No.
---|---|---|---|---|---|---
2.5| A1| 14| 1.8| 3.11| PV-SP4/2,5
PV-BP4/2,5| 32.0506P
32.0106P
4| B1| 12| 2.15| 4.2| PV-SP4/6
PV-BP4/6| 32.0507P
32.0107P
6| C1| 10| 2.4| 4.28| PV-SP4/6
PV-BP4/6| 32.0507P
32.0107P

WZ 2 *60100

MC4-Evo 2

Conductor cross
section
mm²| Coding| Conductor cross
section
AWG| Crimp height
± 0.05 mm| Crimp width
± 0.1 mm| Contact type| Order No.
---|---|---|---|---|---|---
4| B2| 12| 2.16| 4.2| PV-SP4-EVO 2/6
PV-BP4-EVO 2/6| 32.0521P
32.0121P
6| C2| 10| 2.4| 4.28| PV-SP4-EVO 2/6
PV-BP4-EVO 2/6| 32.0521P
32.0121P
10| D2| 8| 3.02| 5.65| PV-SP4-EVO 2/10
PV-BP4-EVO 2/10| 32.0522P
32.0122P

Conductor cross
section
mm²| Coding| Conductor cross
section
AWG| Crimp height
± 0.05 mm| Crimp width
± 0.1 mm| Contact type| Order No.
---|---|---|---|---|---|---
4| B2| 12| 2.16| 4.2| PV-SP4/6
PV-BP4/6| 32.0507P
32.0107P
6| C2| 10| 2.4| 4.28| PV-SP4/6
PV-BP4/6| 32.0507P
32.0107P
10| D2| | 3.02| 5.65| PV-SP4/10
PV-BP4/10| 32.0508P
32.0108P*

• 8 AWG (10 mm²) MC4 makara kıvrımlarının kıvrılması, konektörler için ilgili UL dosyasında listelenmemiştir.
• Crimping of 8 AWG (10 mm²) MC4 barrel crimps is not listed in the related connector UL file.

Visual inspection of the crimpings performed

İmalatçı/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

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