STAUBLI PV-CZM Multi-Contact MC4 Crimp Tool Instruction Manual

STAUBLI PV-CZM Multi-Contact MC4 Crimp Tool

Safety instructions

These assembly instructions and the assembly steps and instructions described are an integral part of and prerequisite for certification by TÜV Rheinland and UL.

Installation, electrotechnical expertise

The products may be assembled and installed by electrically skilled or instructed persons duly observing all applicable safety regulations.

Caution, risk of electric shock

Work in a de-energized state
Follow the five safety rules, when working on electrical installations.
After the respective electrical installations have been identified, the following five essential requirements shall be undertaken in the specified order unless there are essential reasons for doing otherwise:

• disconnect completely;
• secure against re-connection;
• verify absence of operating voltage;
• carry out grounding and short-circuiting;
• provide protection against adjacent live parts
  Any person engaged in this work activity shall be electrically skilled or instructed, or shall be supervised by such a person Source: EN 50110-1:2013

Protection against electric shock shall be checked in the end-use applications too.

Caution

Each time the connector is used, it should previously be inspected for external defects. If there are any doubts as to its safety, a specialist must be consulted.
Use only in accordance with the specification provided in the technical data (see product catalog).
The wearing of suitable protective equipment or the performance of the relevant work is the responsibility of the user.
Components and packaging materials are not toys; small parts can pose a choking hazard if swallowed. Packaging material can pose a risk of suffocation.
Proper disposal of products and packaging materials after use.

Do not disconnect under load
Disconnect Under Load: PV plug connections must not be disconnected while under load.

During no-load operation plugging and unplugging when live is permitted (by switching off the DC/AC converter or breaking the AC circuit).

Explanation for MC4

(ill. 1)
Crimping pliers incl. locator and built-in crimping die

PV-KBT/10…,

PV-KST/10…

| PV-KBT4/8II-UR, PV-KST4/8II-UR| PV-KBT4/5…-UR,
PV-KST4/5…-UR| PV-KBT4/6…-UR,
PV-KST4/6…-UR| PV-KBT4/2,5…-UR,
PV-KST4/2,5…-UR| Typ Type
---|---|---|---|---|---
10 mm2| 8 AWG| 10 AWG| 12 AWG| 14 AWG| 10 AWG| 6 mm2| 12 AWG| 4 mm2| 14 AWG| 2.5 mm2| Leiterquerschnitt Conductor cross section
•| | | | | •| •| •| •| •| •| Offener Crimpkontact (B-Crimp) Open crimp contacts (B-Crimp)
| •| •| •| •| | | | | | | Geschlossener Crimpkontakt (O-Crimp) Closed crimp contacts (O-Crimp)
| | | | | | | •| •| •| •| PV-CZM-18100 32.6020-18100| Crimpzangen 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-ES-CZM-18100 32.6021-18100| Crimpeinsätze Crimping dies
| | | | | •| •| •| •| •| •| PV-ES-CZM-19100 32.6021-19100
| •| | | | •| •| •| •| | | PV-ES-CZM-22100 32.6021-22100
| •| •| •| •| | | | | | | PV-ES-CZM-23100 32.6021-23100
•| | | | | | | •| •| | | PV-ES-CZM-20100 32.6021-20100
•| | | | | •| •| | | | | PV-ES-CZM-21100 32.6021-21100
•| | | | | •| •| •| •| •| •| PV-LOC 32.6040| Lokator Locator
| •| | | | •| •| •| •| | | PV-LOC-B 32.6055
| •| •| •| •| | | | | | | PV-LOC-D 32.6074

Individual parts
(ill. 2 + 3 + 4 + 5 + 6) Interchangeable crimping dies

(ill. 2)

PV-KBT4/2.5…-UR
5| 4| 12| PV-KST4/6…-UR
PV-KBT4/6…-UR
6| 6| 10| PV-KST4/6…-UR
PV-KBT4/6…-UR

(ill. 3)

PV-KBT4/6…-UR
8| 10| PV-KST4/10…-UR
PV-KBT4/10…-UR

(ill. 4)

4 / 10                                PV-ES-CZM-20100 32.6021-20100
| | |

Pos.

| Leiterquerschnitt Cable cross section| geeignet für suitable for
---|---|---
| mm2|
9| 6| | PV-KST4/6…-UR
PV-KBT4/6…-UR
10| 10| | PV-KST4/10…-UR
PV-KBT4/10…-UR
| | 10|
| | 9|
| | | 5

(ill. 5)

6 / 10                                PV-ES-CZM-21100 32.6021-21100
Pos.| Leiterquerschnitt Cable cross section| geeignet für suitable for
---|---|---
| AWG|
11| 8| PV-KST4/8II-UR PV
KBT4/8II-UR
12| 10| PV-KST4/6…-UR
PV-KBT4/6…-UR
13| 12| PV-KST4/6…-UR
PV-KBT4/6…-UR

(ill. 6)

PV-KBT4/5…-UR
16| 14| PV-KST4/5…-UR
PV-KBT4/5…-UR

****(ill. 7)

(ill. 8)
Locator PV-LOC Order No: 32.6040 (ill. 9)
Locator PV-LOC-B Order No: 32.6055

Note: When using the crimping pliers PV-CZM-22100, use the locator PV- LOC-B.

(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.

Explanation for MC4-Evo 2

(ill. 11)
Crimping pliers incl. locator and built-in crimping die

Typ Type| Leiterquerschnitt Conductor cross section| Offener Crimpkontakt (B-Crimp) Open crimp contacts (B-Crimp)| Geschlossener Crimpkontakt (O-Crimp) Closed crimp contacts (O-Crimp)| Crimpzangen Crimping pliers| Crimpeinsätze Crimping dies| Lokator Locator
---|---|---|---|---|---|---

PV-CZM-40100 32.6020-40100

|

PV-CZM-41100 32.6020-41100

|

PV-CZM-42100 32.6020-42100

|

PV-ES-CZM-40100 32.6021-40100

|

PV-ES-CZM-41100 32.6021-41100

|

PV-ES-CZM-42100 32.6021-42100

|

PV-LOC-C 32.6056

PV-KST-EVO 2/2.5…-UR PV-KBT-EVO 2/2.5…-UR| 2.5 mm2| •| | •| •| | •| •| | •
14 AWG| •| | •| •| | •| •| | •
PV-KST-EVO 2/6…-UR,

PV-KBT-EVO 2/6…-UR

| 4 mm2| •| | •| •| •| •| •| •| •
12 AWG| •| | •| •| •| •| •| •| •
6 mm2| •| | •| •| •| •| •| •| •
10 AWG| •| | •| •| •| •| •| •| •
PV-KST-EVO 2/10…-UR, PV-KBT-EVO 2/10…-UR| 10 mm2| •| | | | •| | | •| •
8 AWG| •| | | | •| | | •| •

Individual parts

(ill. 12 + 13 + 14) Interchangeable crimping dies

Pos.

| Leiterquerschnitt Cable cross section| geeignet für suitable for
---|---|---
| mm2| AWG|
1| 1,5| | PV-KST4-EVO 2/2,5…-UR

PV-KBT4-EVO 2/2,5…-UR

2| 2,5| 14| PV-KST4-EVO 2/2,5…-UR

PV-KBT4-EVO 2/2,5…-UR

3| 4| 12| PV-KST4-EVO 2/6…-UR PV-KBT4-EVO 2/6…-UR
| 1| |
| 2| |
| 3| |
| | | 12

(ill. 12)

PV-KBT4-EVO 2/2,5…-UR

5| 4| 12| PV-KST4-EVO 2/6…-UR PV-KBT4-EVO 2/6…-UR
6| 6| 10| PV-KST4-EVO 2/6…-UR PV-KBT4-EVO 2/6…-UR

(ill. 13)

(ill. 14)

(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 com-pletely 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 com-pletely 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 and hold clamp (K).
• Place the contact in the appropriate cross-section range.
• Turn the crimping flaps (C) upwards.
• Release clamp (K).
• The contact is fixed.

(ill. 25)
Verify if the crimping flaps are still correctly aligned.
Press the pliers gently together until the crimping flaps are properly located with-in the crimping die.

(ill. 26)
Insert the stripped cable end until the cable strands come up against the clamp.
Completely close the crimping pliers.

(ill. 27)
Visually check the crimp according to the criteria written in IEC 60352-2:2006

• A1:2013

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:.

MC4| MC4-Evo 2| mm2| AWG| Offener Crimpkontakt (B-Crimp) Open crimp contacts (B-Crimp)| Geschlossener Crimpkontakt (O-Crimp) Closed crimp contacts (O-Crimp)| Kabel Cable| Crimphöhe Crimp height
---|---|---|---|---|---|---|---
PV-KBT4/2,5…-UR| PV-KST4-EVO 2/2.5…-UR PV-KBT4-EVO 2/2.5…-UR

PV-KST4-EVO 2/6…-UR PV-KBT4-EVO 2/6…-UR

PV-KST4-EVO 2/6…-UR PV-KBT4-EVO 2/6…-UR

PV-KST4-EVO 2/10…-UR PV-KBT4-EVO 2/10…-UR

| 2.5

4.0

6.0

10

| 14

12

10

8

14

12

10

8

|

• Flex-Sol-Evo TX 2,5           Flex-Sol-Evo DX 2,5
• Flex-Sol-Evo TX 4,0           Flex-Sol-Evo DX 4,0
• Flex-Sol-Evo TX 6,0           Flex-Sol-Evo DX 6,0
• Flex-Sol-Evo TX 10            Flex-Sol-Evo DX 10
• Flex-Sol-Evo DX 2,5
•   Flex-Sol-Evo DX 4,0
• Flex-Sol-Evo DX 6,0
• Flex-Sol-Evo DX 10

| 1.80
2.15
2.40
3.02
2.20
2.50
2.50
3.12
PV-KST4/2,5…-UR
PV-KBT4/6…-UR
PV-KST4/6…-UR
PV-KBT4/6…-UR
PV-KST4/6…-UR
PV-KBT/10…
PV-KST/10…
PV-KBT4/5…-UR
PV-KST4/5…-UR
PV-KBT4/5…-UR
PV-KST4/5…-UR
PV-KBT4/5…-UR
PV-KST4/5…-UR
PV-KBT4/8II-UR
PVKST4/8II-UR

Good crimp

Bad crimp:

• Stamped parts bent wrongly

• Material flow outwards

• Open crimp wings

• Not included strands

Hersteller/Producer:
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

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