STAUBLI MA704 2.5 mm Conductor Cross Sections Crimping Pliers Instruction Manual

STAUBLI MA704 2.5 mm Conductor Cross Sections Crimping Pliers

Specifications:

• Product Model: MA704
• Crimpzange Model: PV-CZM-…
• Product Overview: Crimping pliers with interchangeable crimping dies and locators

Product Usage Instructions

Safety Instructions:
Make sure to read and understand the safety instructions provided in the manual before using the product. The hand tool is not suitable for live working according to IEC 60900 standards.

Product Overview:
The product includes crimping pliers with interchangeable crimping dies and locators, suitable for various connectors such as MC4 and MC4-Evo 2.

Individual Parts:
The product consists of crimping pliers, locators, MC4 connectors, and crimping dies.

Exchanging the Crimping Die:
Follow the instructions provided in the manual to safely exchange the crimping die based on your specific requirements.

Crimping Process:
Utilize the crimping pliers and appropriate crimping die to securely crimp the connectors. Follow the specified crimping instructions for best results.

Verify the Crimped Assembly:
After crimping, always verify the assembly to ensure a proper and secure connection.

Visual Inspection:
Perform a visual inspection of the crimped connections to check for any irregularities or defects.

FAQ:

1. Q: Can I use the crimping pliers for live working?
   A: No, the hand tool is not suitable for live working as per safety standards (IEC 60900).

2. Q: What should I do after an emergency opening of the crimping pliers?
   A: Discard the metal crimp in process and continue using the crimping pliers for the next operation without any special action.

3. Q: What happens if I use the wrong combination of crimping insert/locator and crimp contact?
   A: Using the wrong combination can result in a compromised and potentially dangerous crimp connection. Always use the correct components as specified in the manual.

Conductor cross sections 2.5 mm², 4 mm², 6 mm²

Conductor cross sections 4 mm², 6 mm², 10 mm²

Conductor cross sections 14 AWG, 12 – 10 AWG, 8 AWG

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.
• Safely store the instruction manual and pass them on to subsequent users.

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).

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.

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.

• 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.

Crimping Kit PV-CZM-64100 32.6020-64100
The kit contains two crimping dies and two locators for crimping of MC4 crimp contacts.
The combination of crimping die 32.6021-61100 and locator 32.6082 is suitable for crimping of open crimp contacts (B-Crimp) with wire sizes 2.5 mm², 4 mm², 6 mm².
The combination of crimping die 32.6021-63100 and locator 32.6085 is suitable for crimping of closed crimp contacts (O-Crimp) with wire sizes 14 AWG, 12 AWG, 10 AWG, 8 AWG.

Note:
Using the wrong combination of crimping insert/ locator and crimp contact can result in a compromised and potentially dangerous crimp connection.

Only use Stäubli crimp dies certified for tool PV-CZM-…
Like for all manual operations, visual inspection of the crimped contact is essential.
Verify the crimped assembly, page 15.

Crimping pliers with crimping dies and locators for open crimp contacts (B-Crimp)

Note:
Crimping pliers in Tab. 1 are only suitable for crimping of open crimp contacts (B-Crimps). Using them for crimping of closed crimp contacts (O-Crimps) can result in a compromised and potentially dangerous crimp connection.

Crimping pliers with crimping die and locator for closed crimp contacts (O-Crimp)

Note:
Crimping pliers in Tab . 2 are only suitable for crimping of closed crimp contacts (O-Crimps)  . Using them for crimping of open crimp contacts (B-Crimps) can result in a compromised and potentially dangerous crimp connection .

Individual parts
(ill. 1)
Interchangeable crimping die for cable cross sections 4 mm², 6 mm² and 10 mm²

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 6.

PV-KBT4/6…-UR
PV-KST4-EVO 2/6…-UR PV-KBT4-EVO 2/6…-UR PV-KST4-EVO 2A/6…
PV-KBT4-EVO 2A/6…
2| 6| 10| PV-KST4/6…-UR
PV-KBT4/6…-UR
PV-KST4-EVO 2/6…-UR PV-KBT4-EVO 2/6…-UR PV-KST4-EVO 2A/6…
PV-KBT4-EVO 2A/6…
3| 10| 8| PV-KST4-EVO 2/10…-UR PV-KBT4-EVO 2/10…-UR PV-KST4-EVO 2A/10…
PV-KBT4-EVO 2A/10…
4| 10| –| PV-KST4/10…
PV-KBT4/10…

(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 ter-minals. The locators with grey metal body must be used only for MC4-Evo 2 crimp terminals .

(ill. 3)
Auswechselbarer Crimpeinsatz für Leiterquerschnitte 2,5 mm², 4 mm² und 6 mm²

PV-KBT4/2.5…-UR
PV-KST4-EVO 2/2.5…-UR
PV-KBT4-EVO 2/2.5…-UR PV-KST4-EVO 2A/2.5…
PV-KBT4-EVO 2A/2.5…
2| 4| 12| PV-KST4/6…-UR
PV-KBT4/6…-UR
PV-KST4-EVO 2/6…-UR PV-KBT4-EVO 2/6…-UR PV-KST4-EVO 2A/6…
PV-KBT4-EVO 2A/6…
3| 6| 10

(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.

(ill. 5)
Interchangeable crimping die for cable cross sections 14 AWG, 12 AWG, 10 AWG und 8 AWG.

• Crimping of MC4 barrel crimps.

AWG
1| 14| PV-KST4/5…-UR
PV-KBT4/5…-UR
2| 12 – 10| PV-KST4/5…-UR
PV-KBT4/5…-UR
3| 8| PV-KST4/8…-UR
PV-KBT4/8…-UR

(ill. 6)
Locator:
MC4 connectors: PV-LOC-MC4 Order No. 32.6085

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. 7)

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

(ill. 8)

• Unscrew screw S (long) and S1 (short) completely using an Allen key 2.5 mm (is included in 63100 set of pliers only).
• Open the crimping pliers.

(ill. 9)

• Remove the upper crimping die.

(ill. 10)

• Remove the lower crimping die.

Fitting the crimping die
(ill. 11)
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. 12)

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

Locator assembly

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

(ill. 13)

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

Crimping
(ill. 14)

• 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. 15)

• 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. 16)

• 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. 17)
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. 18)
For crimping closed crimp contacts (O-Crimp)

• Place the contact in the appropriate cross-section range.

Verify the crimped assembly

(ill. 19)
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:

*Crimping tool 61100 for crimping open crimp contacts (B-Crimp) MC4-Evo 2**

 Conductor cross section mm²|  Coding|  Conductor cross section
AWG|  Metall- kontakt
Crimp height
± 0.05 mm|  Metall- kontakt
Crimp width± 0.1 mm|  Contact type| Bestell-Nr. 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| 4.20| 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*

*Crimping tool 61100 for crimping open crimp contacts (B-Crimp) MC4**

 Conductor cross section mm²| **** Coding| Conductor cross section

AWG

| Metall- kontakt
Crimp height
± 0.05 mm|  Metall- kontakt
Crimp width
± 0.1 mm| Contact type| Bestell-Nr. 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| 4.20| 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

*Crimping tool 60100 for crimping open crimp contacts (B-Crimp) MC4-Evo 2**

 Conductor cross section mm²|  Coding|  Conductor cross section

AWG

|  Metall- kontakt
Crimp height
± 0.05 mm|  Metall- kontakt
Crimp width
± 0.1 mm|  Contact type| Bestell-Nr. Order No.
---|---|---|---|---|---|---
4| B2| 12| 2.15| 4.20| 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

*Crimping tool 60100 for crimping open crimp contacts (B-Crimp) MC4**

 Conductor cross section mm²|  Coding|  Conductor cross section
AWG|  Metall- kontakt
Crimp height
± 0.05 mm|  Metall- kontakt
Crimp width
± 0.1 mm| Contact type| Bestell-Nr. Order No.
---|---|---|---|---|---|---
4| B2| 12| 2.15| 4.20| 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| ****

1)

| 3.02| 5.65| PV-SP4/10 PV-BP4/10| 32.0508P
32.0108P

Note:
Crimping of 8 AWG (10 mm²) MC4 barrel crimps is not listed in the related connector UL file.

*Crimping tool 63100 for crimping closed crimp contacts (O-Crimp) MC4**

 Conductor cross section AWG|  Coding| Crimp height wire

± 0.05 mm

|  Crimp width wire
± 0.05 mm|  Contact type|  Order No.
---|---|---|---|---|---
14| E1| 2.2| 3.8| PV-SP4/5 PV-BP4/5| 32.0524
32.0124
10 – 12| F1| 2.5| 3.83| PV-SP4/5 PV-BP4/5| 32.0524
32.0124
8| G1| 3.01| 5.26| PV-SP4/8 PV-BP4/8| 32.0523
32.0119

Visual inspection of the manufactured crimps
Good crimp

Bad crimps:

Notes

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

© by Stäubli Electrical Connectors AG, Switzerland – MA704 – 09.2024, Index c, Marketing Communications – Änderungen vorbehalten/Subject to alterations

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