(R) Multi-Contact 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 MA241 Assembly instructions US 01 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 - For U.S. Distribution Only UL Recognized Connectors and Junction Boxes US 01 1/8 (R) Multi-Contact 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 MA241 Assembly instructions MC Connector system for Photovoltaics 600 V DC - UL Recognized - 20A-30A US 01 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. Male Cable Connector Series I, II, III, & 6III Parts list PV-KST3I-UR PV-KST3II-UR PV-KST3III-UR PV-KST3/6III-UR Type A B Order No dia.mm mm PV-KST3I-UR PV-KST3II-UR PV-KST3III-UR PV-KST3/6III-UR 32.0001-UR 32.0003-UR 32.0005-UR 32.0007-UR 13.5 13.5 13.5 13.5 41.6 41.6 51.6 51.6 1) di 3 D A B 2) D dia.mm D 2) mm 3.2-4.8 4.9-7.1 6.5-93) 6.5-93) 2-4 2-4 2-4 6 Pin Insulator PV-T3I/S-UR PV-T3II/S-UR PV-T3III/S-UR PV-T3III/S-UR Pin dia. 3 mm 32.0701-UR 32.0703-UR 32.0705-UR 32.0705-UR PV-SP3/4 PV-SP3/4 PV-SP3/4 PV-SP3/6 32.0500 32.0500 32.0500 32.0502 di dia.mm 3 3 3 4 Female Cable Connector Series I, II, III, & 6III di dia.3 Parts list PV-KBT3I-UR PV-KBT3II-UR PV-KBT3III-UR PV-KBT3/6III-UR Type A B Order No dia.mm mm PV-KBT3I-UR PV-KBT3II-UR PV-KBT3III-UR PV-KBT3/6III-UR 32.0000-UR 32.0002-UR 32.0004-UR 32.0006-UR 1) Cable outer diameter 2/8 13.5 13.5 13.5 13.5 40 40 50 50 1) 2) D dia.mm D 2) mm 3.2-4.8 4.9-7.1 6.5-93) 6.5-93) 2-4 2-4 2-4 6 2) Cable cross section Pin Insulator PV-T3I/B-UR PV-T3II/B-UR PV-T3III/B-UR PV-T3III/B-UR Pin dia. 3 mm 32.0700-UR 32.0702-UR 32.0704-UR 32.0704-UR PV-BP3/4 PV-BP3/4 PV-BP3/4 PV-BP3/6 32.0100 32.0100 32.0100 32.0101 di dia.mm 3 3 3 4 3) With assembly device PV-RWZ, up to 8mm ida.; pre-assembled cable up to 9mm dia. (R) Multi-Contact 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 MA241 Assembly instructions MC Connector system for Photovoltaics 600 V DC - UL Recognized - 20A-30A US 01 - 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 89 8 30 24 2 1 1 110.5 2 95 89 dia. 1-1.5 95 = Type PV-JB/2-UR Order No. 32.7000-UR 36 = 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: -40C to +40C Derating diagram of a single PV-Connection A 25 Rated current 1) 20 15 10 2.5 mm in free air 4 mm in free air 2.5 mm in conduit 4 mm in conduit 5 0 20 30 40 50 60 70 80 90 C Ambient temperature According to IEC 264-5-523 1) 3/8 (R) Multi-Contact 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 MA241 Assembly instructions MC Connector system for Photovoltaics 600 V DC - UL Recognized - 20A-30A US 01 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 PV-CZL Selector ill.1 Locator PV-WZ3 PV-WZ3/III 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. (ill.1) - Only acceptable crimping tool - PV-CZL (size I, II) Order # . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.6001 (size III / 6III) . . . . . . . . . . . . . . . . . . . . . . . . . . contact Multi-Contact USA (ill.2) - Only acceptable assembly tool - PV-WZ3 (size I, II) Order # . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.6000 - Only acceptable assembly tool - PV-WZ3/III (size I / II / III) Order # . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.6002 ill.2 G ill.3 H Cable preparation Maximum operating ambiant temperature for full load conditions is 70 C for 14 AWG and 75 C for other wire sizes. (ill.3) - Check diameter. G = I.D. insulator ill.4 max. 1 mm H = O.D. over cable insulation G 2.8 mm 4.0 mm 6.0 mm 6.0 mm Series I Series II Series III Series 6III H 3.2 mm - 4.8 mm 4.9 mm - 7.1 mm 6.5 mm - 9 mm 6.5 mm - 9 mm (ill.4) - Strip cable insulation Type PV-BP3/4 PV-SP3/4 PV-SP3/6 PV-BP3/6 Q Length L (mm) 6.5 - 7.5 6.5 - 7.5 8.5 - 9.5 8.5 - 9.5 Crimping ill.5 SEL. 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. (ill.6) - Selector position according to chart: Cable cross section 2.5mm 4.0mm 6.0mm 14AWG 12AWG 10AWG 7 No. 6 543 21 (ill.5) - Insert cable into crimp sleeve up to stop. Stranded conductor must be visible in the sight hole (Q). 8 ill.6 Crimp tools Order No. PV-CZL 32.6001 Selector position 3 4 4 5 5 6 *contact Multi-Contact USA 4/8 (R) Multi-Contact 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 MA241 Assembly instructions US 01 L 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: Assembly tool L ill.7 PV-WZ3 32.6000 PV-WZ3/III 32.6002 E ill.8 A D B 23.5 mm 1 mm 13.5 mm 1 mm (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.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, at the same time, push in the pin / socket applying pressure to the cable. - With the lever in the end position, pull of the mounted pin/socket with insulator. ill.9 Note: To facilitate installation, immerse the insulation of plug connectors in ethyl alcohol before inserting the contacts. Ethyl or industrial alcohol C K E D ill.10 (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.12) - Supplied tags "DANGER DO NOT DISCONNECT UNDER LOAD" to be attached to cables during installation. a. Peel tag from backing. Align on wire. Press layers together. Keep fingertips away from adhesive surfaces. (ill.13) - Make sure connectors are fully engaged without a gap between the insulators. ill.11 ill.12 ill.13 5/8 (R) Multi-Contact 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 MA241 Assembly instructions MC Connector system for Photovoltaics 600 V DC - UL Recognized - 20A-30A US 01 89 8 30 24 2 1 1 110.5 2 95 89 dia. 1-1.5 95 = Type PV-JB/2-UR Order No. 32.7000-UR 36 = The standard type of MC PV junction box is delivered with 2 terminal clips 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. 1 - Rated voltage: . . . . . . . . . . . . . . . . . . . . . . . 600 V DC maximum - Rated current: . . . . . . . . . . . . . . . . . . . . . . . . 20 A DC maximum - Operating range: . . . . . . . . . . . . . . . . . . . . . . . . . -40C to +40C Tools required (ill.14) - Screwdriver size 1 to open the spring clamp in the junction box and to open the cover of the junction box. ill.14 Installation of junction box to the back of the PV module B A B 95 8 9 10 234 11121 Zusatzbez. (DIN 6120/2) 567 Kunststofftyp (DIN 7728/1) ill.15 6/8 (ill.15) (R) - In case of Tedlar material, clean the back of the PV module with isopropyl 1) alcohol . In case of glass, clean with isopropyl alcohol1) and then apply Silan Glass Primer1) 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. (R) Multi-Contact 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 MA241 Assembly instructions MC Connector system for Photovoltaics 600 V DC - UL Recognized - 20A-30A US 01 Adhesives and primers B Adhesive / Silicone / Polyurethane1) B PV-AK 3 600V / 4 mm C 95 8 9 10 234 11121 Zusatzbez. (DIN 6120/2) Primer1) 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 Dow Corning grey - - 567 Kunststofftyp (DIN 7728/1) 2) Sylgard 577 D 1) 2) D Observe the manufacturer's instructions for use UL recognized Connecting the conductors ill.16 (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. E PV-AK 3 600V / 4 mm (ill.17) - Cut and shape wire ends of diode (E) as required. Plug bypass diode in to terminal. (Observe the polarity). 95 8 9 10 234 11121 Zusatzbez. (DIN 6120/2) 567 Kunststofftyp (DIN 7728/1) E ill.17 1/4 Closing the junction box (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. 2 2 1 1 ill.18 SAFETY PRECAUTIONS 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. 7/8 (R) Multi-Contact 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 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: NORTHWEST / CANADA 4870 Baytree Court Burnaby, BC, Canada V5G4H3 Tel. (604) 451-7808 Fax (604) 451-7809 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 WEST 5521 / 265 Scotts Valley Drive Scotts Valley, CA 95066 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 SOUTHERN CALIFORNIA 2061 Pueblo Tustin Ranch, CA Tel. (831) 430-9272 Fax (831) 430-9278 8/8 - For U.S. Distribution Only - MA241 01/07 Index b SOUTHEAST 2947 San Jeronimo Road Port St. Lucie, FL 34952 Tel. (561) 335-5444 Fax (561) 335-4991 Anderungen vorbehalten/Subject to alterations/Modifications sous reserve Copyright by Multi-Contact AG, Switzerland MC-Solarline 500-01/07