STAUBLI MA710 PV Male Cable Coupler Instruction Manual

MA710
Assembly instructions
PV male cable coupler PV-KST4/13II-UR
PV female cable coupler PV-KBT4/13II-UR

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, fire, 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.

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

(ill. 2)
Assembly and unlocking tool PV-MS-PLS, Order No. 32.6058
or
Open-end spanner set PV-MS, Order No. 32.6024

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

(ill. 3)
PV-CZLX/6AWG incl. locator, Order No. 32.0349

(ill. 4)
PV-WZ-Torque-Set, Order No. 32.0065

(ill. 5)
Test plug PV-PST Order No. 32.6028

(ill. 6)
Open-end spanner wrench 15 mm
(ill. 7)
Torque wrench 12 mm (1/2” drive)
(ill. 8)
Cable cutter PV-WZ-KS, Order No. 32.6080
Note:
Operating instructions MA705,
www.staubli.com/electrical

Guideline for connector configuration

Cable preparation

For selection of approved cable please follow these guidelines.
Attention:
For PV-KST4/13II-UR and PV-KBT4/13II-UR tinned copper or uncoated (bare) copper conductors can be used. Do not use already oxidized conductors. For safety reasons, Stäubli prohibits the use of PVC cables.

(ill. 9)
Check dimensions A and b, see Tab. 1.
Note:
In case that other diameters than those mentioned in Tab. 1 are used please contact Stäubli.

Selection of suitable UL certified cable
(Tab. 1)
Cables connected to the connectors shall be suitable for use in photovoltaic systems and shall comply with the requirements of ZKLA (PV Wire).

(ill. 10)
After stripping the cable insulation verify distance L.
L = 7.5 mm to 9 mm
Attention:
Do not cut strands when stripping the cable!

Crimping

(ill. 11)
Set selector knob to selector no. 5. To do so remove spring clip from selector knob and rotate until selector number is in line with index mark. Replace spring clip (optional).

(ill. 12)
Fully insert the contact into the locator.

(ill. 13)
Insert the stripped cable end until the lead strands come up against the clamp.

(ill. 14)
Completely close the crimping pliers, until the ratched releases.

(ill. 15)
Remove crimped contact and wire.

(ill. 16)
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

Gaging Instructions

To verify proper calibration of the tool, go’ andno-go’ gage pins can be used.
Change crimp setting to number 5 and operate the tool to a fully closed position.
Maintain firm hand pressure on the tool handles. Insert a go’ gage pin with diameter .1420’’ between the crimp indenter tips. Thego’ gage should freely pass.
You can also use a `no-go’ gage pin with diameter .1520’’.
This pin may partially enter the indenter opening, but must not pass completely through the the opening.

Assembly check

(ill. 17)
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. 18)
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.

(ill. 19)

• Pre-tighten cable gland with tools
  PV-MS or PV-MS-PLS.

• tighten cable gland using PV-WZ-Torque-Set, while supporting the insulator front with PV-MS or PVMS-PLS. The tightening torque must be appropriate for the solar cables used.
  Typical values are between 3.4 and 3.5 N m 1) .

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

Mating
(ill. 20)
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 assembly has to be verified at all times.

Disconnecting

(ill. 21)
Push the unlocking pins of PV-MS or PV-MS-PLS onto the locking clips (X) 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

Cable management must allow a minimum of 20 mm of cable that exits directly from the cable seal without bending or stress.
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 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 that 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

Degree of protection,  mated
unmated| IP65/IP68 (1 m, 1 h)
IP2X
Overvoltage category/Pollution degree| CAT III/3
Contact resistance| 0,25 mΩ
Polarity of the connectors| Buchse/Socket = Plus/positive
Stecker/Plug = Minus/negative
Locking system| Locking type
Contact system| MULTILAM
Type of termination| Crimpen/Crimping
Safety instruction| Nicht unter Last trennen
Do not disconnect under load
Contact material| Kupfer, verzinnt/Copper, tin plated
Insulation material| PC/PA
Flame class| UL94-V0
Salt mist spray test, degree of severity 6| ja/yes
Ammonia resistance (according to DLG)| ja/yes
UL certified according to UL 6703| E343181

1. Engineering considerations: This is the maximum rated current of the connector. The final current ratings have to be verified in the end-use application. The maximum operating temperature of the connector shall not be exceeded.

Manufacturer and support location:
Stäubli Electrical Connectors, Inc.
100 Market Street
Windsor, CA 95492/United States
Phone +1 707 838 0530
Fax +1 707 838 2474
mail ec.us@staubli.com
www.staubli.com/electrical| Global headquarters:
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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© by Stäubli Electrical Connectors AG, Switzerland – MA710 – 05.2022 – Index a Marketing Communications – Änderungen vorbehalten/Subject to alterations

References

• Electrical connectors for reliable, safe and durable solutions - Stäubli

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