Multi-Contact AG, Stockbrunnenrain 8, Postfach, CH-4123 Allschwil 1, Tel.: 061/306 55 55, Fax: 061/306 55 56, Internet: www.multi-contact.com, E-Mail: basel@multi-contact.com
®
Multi-Contact
MULTI-CONTACT USA
PRECISION ELECTRICAL & ELECTRONIC CONNECTORS
MC “Plug-n-Play” Connector System
for Photovoltaic Applications
600 V DC 20A-30A
UL File# E181720
For time-saving, safe and
reliable cabling of
PV-Modules
Multi-Contact USA
5560 Skylane Blvd.
Santa Rosa, CA 95403
Installation Instructions
UL Recognized Connectors and Junction Boxes
- For U.S. Distribution Only -
US 01
1/8
MA241
Assembly instructions US 01
®
Multi-Contact
MC Connector system for Photovoltaics
600 V DC - UL Recognized - 20A-30A
Male Cable Connector Series I, II, III, & 6III
The components of the MC “Plug-n-Play” connector system for photovoltaics (PV) are designed to permit
time-saving, dependable cabling of solar modules which are free-standing or integrated into buildings.
MC PV “Plug-n-Play” connector system permits preassembly of the PV modules at the factory or in the
field. The equipment can be installed quickly by skilled construction workers. Benefit: Traditionally high
installation costs for these modules are cut sharply.
B
D
A
PV-KST3I-UR
PV-KST3II-UR
PV-KST3III-UR
PV-KST3/6III-UR
PV-KST3I-UR 32.0001-UR 13.5 41.6 3.2-4.8 2-4
PV-KST3II-UR 32.0003-UR 13.5 41.6 4.9-7.1 2-4
PV-KST3III-UR 32.0005-UR 13.5 51.6 6.5-9 2-4
PV-KST3/6III-UR 32.0007-UR 13.5 51.6 6.5-9 6
3)
3)
Type Order No dia.mm mm dia.mm mm2)
AB D D
1) 2)
PV-T3I/S-UR 32.0701-UR PV-SP3/4 32.0500 3
PV-T3II/S-UR 32.0703-UR PV-SP3/4 32.0500 3
PV-T3III/S-UR 32.0705-UR PV-SP3/4 32.0500 3
PV-T3III/S-UR 32.0705-UR PV-SP3/6 32.0502 4
Pin Insulator Pin dia. 3 mm dia.mm
di
3
Parts list
PV-KBT3I-UR
PV-KBT3II-UR
PV-KBT3III-UR
PV-KBT3/6III-UR
PV-T3I/B-UR 32.0700-UR PV-BP3/4 32.0100 3
PV-T3II/B-UR 32.0702-UR PV-BP3/4 32.0100 3
PV-T3III/B-UR 32.0704-UR PV-BP3/4 32.0100 3
PV-T3III/B-UR 32.0704-UR PV-BP3/6 32.0101 4
Pin Insulator Pin dia. 3 mm dia.mm
PV-KBT3I-UR 32.0000-UR 13.5 40 3.2-4.8 2-4
PV-KBT3II-UR 32.0002-UR 13.5 40 4.9-7.1 2-4
PV-KBT3III-UR 32.0004-UR 13.5 50 6.5-9 2-4
PV-KBT3/6III-UR 32.0006-UR 13.5 50 6.5-9 6
3)
3)
Type Order No dia.mm mm dia.mm mm2)
AB D D
1) 2)
dia.3
di
Female Cable Connector Series I, II, III, & 6III
Parts list
1) Cable outer diameter 2) Cable cross section 3) With assembly device PV-RWZ, up to 8mm ida.; pre-assembled cable up to 9mm dia.
2/8
MA241
Assembly instructions US 01
di
di
Multi-Contact AG, Stockbrunnenrain 8, Postfach, CH-4123 Allschwil 1, Tel.: 061/306 55 55, Fax: 061/306 55 56, Internet: www.multi-contact.com, E-Mail: basel@multi-contact.com
®
Multi-Contact
2
11
2
Type Order No.
PV-JB/2-UR 32.7000-UR
The standard type of MC PV junction box is delivered with 2 terminal clips
Rated voltage: 600V Rated current: 20 A
Operating range at full load: -40°C to +40°C
89
8
89
95
95
30
24
dia. 1-1.5
110.5
36
==
- Caution -
Unplugging Under Load: PV plug connections must not be unplugged while
under load. They can be placed in a no load state by switching off the DC / AC
convertor of breaking the AC circuit. Plugging and unplugging while under
tension is permitted.
Junction Box - Model PV-JB/2-UR
A
25
20
15
10
20 30 40 50 60 70 80 90 C°
5
0
Rated current 1)
Ambient temperature
According to IEC 264-5-523 1)
Derating diagram of a single PV-Connection
2.5 mm² in free air
4 mm² in free air
2.5 mm² in conduit
4 mm² in conduit
3/8
MC Connector system for Photovoltaics
600 V DC - UL Recognized - 20A-30A
MA241
Assembly instructions US 01
Multi-Contact AG, Stockbrunnenrain 8, Postfach, CH-4123 Allschwil 1, Tel.: 061/306 55 55, Fax: 061/306 55 56, Internet: www.multi-contact.com, E-Mail: basel@multi-contact.com
MC Connector system for Photovoltaics
600 V DC - UL Recognized - 20A-30A
PV-Male cable connector PV-KST3I-UR . . . . . . . . . . . . . . . . . . . . 32.0001-UR
PV-Female cable connector PV-KBT3I-UR . . . . . . . . . . . . . . . . . . 32.0000-UR
PV-Male cable connector PV-KST3II-UR . . . . . . . . . . . . . . . . . . . 32.0003-UR
PV-Female cable connector PV-KBT3II-UR . . . . . . . . . . . . . . . . . 32.0002-UR
PV-Male cable connector PV-KST3III-UR . . . . . . . . . . . . . . . . . . . 32.0005-UR
PV-Female cable connector PV-KBT3III-UR . . . . . . . . . . . . . . . . . 32.0004-UR
PV-Male cable connector PV-KST3/6III-UR . . . . . . . . . . . . . . . . . 32.0007-UR
PV-Female cable connector PV-KBT3/6III-UR . . . . . . . . . . . . . . . 32.0006-UR
(ill.1)
- Only acceptable crimping tool - PV-CZL
(size I, II) Order # . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(size III / 6III) . . . . . . . . . . . . . . . . . . . . . . . . . . contact Multi-Contact USA
32.6001
(ill.3)
- Check diameter.
G = I.D. insulator H = O.D. over cable insulation
(ill.4)
- Strip cable insulation
(ill.5)
- Insert cable into crimp sleeve up to stop. Stranded conductor must be
visible in the sight hole (Q).
(ill.6)
- Selector position according to chart:
Cable preparation
Crimping
(ill.2)
- Only acceptable assembly tool - PV-WZ3
(size I, II) Order # . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Only acceptable assembly tool - PV-WZ3/III
(size I / II / III) Order #. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32.6000
32.6002
The use of parts and tools other than those stated by MC or
disregarding these preparation instructions, can have an effect on safety and
quality.
Maximum operating ambiant temperature for full load conditions is
70° C for 14 AWG and 75° C for other wire sizes.
Caution: Make sure all conductor wires are cleanly inserted into hole and
max. dimension of 1 mm is not exceeded. Crimp the sleeve with crimping
tool.
MA241
Assembly instructions
GH
Series I 2.8 mm 3.2 mm - 4.8 mm
Series II 4.0 mm 4.9 mm - 7.1 mm
Series III 6.0 mm 6.5 mm - 9 mm
Series 6III 6.0 mm 6.5 mm - 9 mm
Type Length L (mm)
PV-BP3/4 6.5 - 7.5
PV-SP3/4 6.5 - 7.5
PV-SP3/6 8.5 - 9.5
PV-BP3/6 8.5 - 9.5
Crimp tools
PV-CZL 32.6001 Selector position
Cable cross section
Order No. 14AWG 12AWG 10AWG
2.5mm² 4.0mm² 6.0mm²
344556
*contact Multi-Contact USA
Locator ill.1
PV-CZL
PV-WZ3
PV-WZ3/III
Selector
ill.2
H
G
Qmax. 1 mm
1
2
3
4
5
6
7
8
SEL.
No.
ill.3
ill.4
ill.5
ill.6
US 01
®
Multi-Contact
4/8
Multi-Contact AG, Stockbrunnenrain 8, Postfach, CH-4123 Allschwil 1, Tel.: 061/306 55 55, Fax: 061/306 55 56, Internet: www.multi-contact.com, E-Mail: basel@multi-contact.com
MC Connector system for Photovoltaics
600 V DC - UL Recognized - 20A-30A
PV-Male cable connector PV-KST3I-UR . . . . . . . . . . . . . . . . . . . . 32.0001-UR
PV-Female cable connector PV-KBT3I-UR . . . . . . . . . . . . . . . . . . 32.0000-UR
PV-Male cable connector PV-KST3II-UR. . . . . . . . . . . . . . . . . . . . 32.0003-UR
PV-Female cable connector PV-KBT3II-UR. . . . . . . . . . . . . . . . . . 32.0002-UR
PV-Male cable connector PV-KST3III-UR . . . . . . . . . . . . . . . . . . . 32.0005-UR
PV-Female cable connector PV-KBT3III-UR . . . . . . . . . . . . . . . . . 32.0004-UR
PV-Male cable connector PV-KST3/6III-UR. . . . . . . . . . . . . . . . . . 32.0007-UR
PV-Female cable connector PV-KBT3/6III-UR. . . . . . . . . . . . . . . . 32.0006-UR
(ill.7)
- Adjust the assembly tool before assembly. With the drawbar extended, set
the dimension L to:
(ill.8)
- Push tapered spindle (E) through insulator until the end is nearly flush with
insulator.
(ill.9)
- Slip on counter piece (D) from the front. For sockets, side A towards the
insulator. For pins, side B towards the insulator.
(ill.11)
- Check to make sure the insulation is properly engaged on the metal part. If
the installed parts have been assembled correctly, they will be flush with the
end of the insulator.
(ill.13)
- Make sure connectors are fully engaged without a gap between the insula-
tors.
(ill.12)
- Supplied tags “ ” to be
attached to cables during installation.
DANGER DO NOT DISCONNECT UNDER LOAD
a. Peel tag from backing. Align on wire. Press layers together. Keep fingertips away from
adhesive surfaces.
(ill.10)
- Attach tapered spindle (E) to the pull rod (K) of mounting tool (C) and
actuate lever until counter piece (D) reaches the bracket.
- Insert socket or pin into hole of tapered spindle.
- Carefully shift lever to its stop position and, the
pin / socket applying pressure to the cable.
- With the lever in the end position, pull of the mounted pin/socket with
insulator.
at the same time, push in
MA241
Assembly instructions
ill.7
ill.8
Assembly tool L
PV-WZ3 23.5 mm ± 1 mm
PV-WZ3/III 13.5 mm ± 1 mm
32.6000
32.6002
L
D
A
B
E
K
CED
ill.9
ill.11
ill.12
ill.10
Ethyl or industrial alcohol
Note: To facilitate
installation,
immerse the
insulation of
plug connectors
in ethyl alcohol
before inserting
the contacts.
US 01
®
Multi-Contact
5/8
Multi-Contact AG, Stockbrunnenrain 8, Postfach, CH-4123 Allschwil 1, Tel.: 061/306 55 55, Fax: 061/306 55 56, Internet: www.multi-contact.com, E-Mail: basel@multi-contact.com
ill.13
The use of parts and tools other than those stated by MC or disregarding these preparation instructions,
can have an effect on safety and quality.
MC Connector system for Photovoltaics
600 V DC - UL Recognized - 20A-30A
- Rated voltage:. . . . . . . . . . . . . . . . . . . . . . . 600 V DC maximum
- Rated current: . . . . . . . . . . . . . . . . . . . . . . . . 20 A DC maximum
- Operating range: . . . . . . . . . . . . . . . . . . . . . . . . . -40°C to +40°C
(ill.14)
- Screwdriver size 1 to open the spring clamp in the junction box and to open
the cover of the junction box.
(ill.15)
- In case of Tedlar material, clean the back of the PV module with isopropyl
alcohol . In case of glass, clean with isopropyl alcohol and then apply Silan
Glass Primer at the place where the junction box is to be mounted. Use
only purified benzine to clean the junction boxes of grease. Apply silicone or
polyurethane adhesive (A) to the floor of the junction box. We recommend
using the adhesives shown on the following page. The best results are
achieved when the junction box floor is pretreated with one of the listed
primers.
- The compounds must be used in accordance with the manufacturer’s
instructions.
- Lead the ribbon band conductor (B) through the floor of the junction box.
Align junction box and press firmly against the rear wall of the module until
adhesive bulges out evenly on either side of the junction box floor. Allow
adhesive to harden.
®
1) 1)
1)
MA241
Assembly instructions
ill.14
ill.15
2
11
2
Type Order No.
PV-JB/2-UR 32.7000-UR The standard type of MC PV junction box is delivered with 2 terminal clips
89
8
89
95
95
30
24
dia. 1-1.5
110.5
36
==
1
Zusatzbez.(DIN 6120/2)Zusatzbez.(DIN 6120/2)
Kunststofftyp(DIN 7728/1)Kunststofftyp(DIN 7728/1)
9595
12
9
8
7
6
5
4
3
2
1
11
10
B
B
A
Tools required
Installation of junction box to the back of the PV module
US 01
®
Multi-Contact
6/8
Multi-Contact AG, Stockbrunnenrain 8, Postfach, CH-4123 Allschwil 1, Tel.: 061/306 55 55, Fax: 061/306 55 56, Internet: www.multi-contact.com, E-Mail: basel@multi-contact.com
MC Connector system for Photovoltaics
600 V DC - UL Recognized - 20A-30A
MA241
Assembly instructions
B
D
B
C
D
10
11
11
1
2
3
4
5
6
7
8
9
12
95
Zusatzbez.(DIN 6120/2)
Kunststofftyp(DIN 7728/1)
PV-AK 3
600V / 4 mm²
E
E
Zusatzbez.(DIN 6120/2)
Kunststofftyp(DIN 7728/1)
9595
12
9
8
7
6
5
4
3
2
1
1111
10
600V / 4 mm²
PV-AK 3PV-AK 3
2
11
2
1/4
(ill.20)
- Cut ribbon conductor (B) to the required length.
- Open the terminal clip (D) with the screwdriver (C). Bend the ribbon band
and insert in to the terminal clip. Close the terminal clip.
(ill.18)
- The lid of the panel receptacle has a snap-catch in each corner. To close,
simply snap in. To open, insert a size 1 screwdriver in to each opening at
each corner and rotate through a quarter turn. Pull lightly and lift up the lid.
(ill.17)
- Cut and shape wire ends of diode (E) as required. Plug bypass diode in to
terminal. (Observe the polarity).
Adhesives and primers
Closing the junction box
Connecting the conductors
Adhesive / Silicone / Polyurethane Primer
1) 1)
Designation Manufacturer Color Designation Manufacturer
Elastosil N199 Wacker Chemie transparent Primer C790 Wacker Chemie
Typ 744 Dow Corning white - -
Typ 221 Sika Chemie GmbH white & black Sika Primer 210T Sika Chemie GmbH
Loctite 3951 Loctite black Loctite 7251 Loctite
Sylgard 577 Dow Corning grey - -
2)
The use of parts and tools other than those stated by MC or disregarding these preparation instructions, can
have an effect on safety and quality.
For protection against electrical shock, PV connectors must be isolated from the power supply while being
assembled or disassembled.
SAFETY PRECAUTIONS
ill.16
ill.17
ill.18
1) Observe the manufacturer’s instructions for use
2) UL recognized
US 01
®
Multi-Contact
7/8
Multi-Contact AG, Stockbrunnenrain 8, Postfach, CH-4123 Allschwil 1, Tel.: 061/306 55 55, Fax: 061/306 55 56, Internet: www.multi-contact.com, E-Mail: basel@multi-contact.com
®
Multi-Contact
MA241 Änderungen vorbehalten/Subject to alterations/Modifications sous réserve
01/07 Index b Copyright by Multi-Contact AG, Switzerland MC-Solar 500-01/07
line
MULTI-CONTACT USA
PRECISION ELECTRICAL & ELECTRONIC CONNECTORS
U.S. Headquarters:
Multi-Contact USA
5560 Skylane Boulevard - Santa Rosa, CA 95403
Tel. (707) 575-7575 - Fax (707) 575-7373
e-mail: aztecman@sonic.net - www.multi-contact-usa.com
Regional Sales Offices:
- For U.S. Distribution Only -
NORTHWEST / CANADA
4870 Baytree Court
Burnaby, BC, Canada V5G4H3
Tel. (604) 451-7808
Fax (604) 451-7809
WEST
5521 / 265 Scotts Valley Drive
Scotts Valley, CA 95066
Tel. (831) 430-9272
Fax (831) 430-9278
SOUTHERN CALIFORNIA
2061 Pueblo
Tustin Ranch, CA
Tel. (831) 430-9272
Fax (831) 430-9278
SOUTH-CENTRAL
2111 / 102 S. Collins Street
Arlington, TX 76010
Tel. (817) 543-0031
Fax (817) 277-5111
GREAT LAKES
3348 Innsbrook Drive
Rochester Hills, MI 48309
Tel. (248) 375-8140
Fax (248) 375-8141
MID-ATLANTIC
633 Leopard Lane
Warminster, PA 76010
Tel. (215) 443-2405
Fax (215) 443-2406
SOUTHEAST
2947 San Jeronimo Road
Port St. Lucie, FL 34952
Tel. (561) 335-5444
Fax (561) 335-4991
MIDWEST
901 Winslow Avenue
Woodstock, IL 60098
Tel. (815) 334-9530
Fax (815) 334-9529
SOUTHWEST
10101East Chestnut Drive
Sun Lakes, AZ 85248
Tel. (480) 883-3878
Fax (480) 883-7919
NORTHEAST
35 Hemlock Drive
Norwell, MA 02061
Tel. (781) 659-9399
Fax (781) 659-9383
8/8
Multi-Contact AG, Stockbrunnenrain 8, Postfach, CH-4123 Allschwil 1, Tel.: 061/306 55 55, Fax: 061/306 55 56, Internet: www.multi-contact.com, E-Mail: basel@multi-contact.com
