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Stäubli Photovoltaic Product Manager Brian Mills and Stäubli Marketing Coordinator Kayla Tescallo talked with AZoM and answered questions about their original MC4 electrical connector (the most widely used photovoltaic cable coupler in the world).

Stäubli is headquartered in Pfäffikon, Switzerland. It was originally established in 1892 and currently has offices in 29 different countries and more than 5,500 employees. Our company has four main business units: robotics, textiles, fluid connectors and electrical connectors. Stäubli acquired Multi Contact (a private company founded in 1963) to form its electrical connector division. The Multi Contact name was discontinued in 2017 and is now called Stäubli electrical connectors.

Staubli offers a wide range of electrical connector products, from large switchgear connectors to miniature PCB connections. One of our most famous product groups is our photovoltaic product portfolio. Staubli was a pioneer in the photovoltaic cable coupler industry in the early 1990s, completely changing the interconnection of photovoltaic modules, and its development is still in use today.

As we all know, MC3 has become the most widely used and most recognized connector in the world. The MC3 connector is the first connector that truly proves that it is a product that can last for more than 20 years without problems. In the early 2000s, in response to the rapidly changing new requirements of the photovoltaic industry, the MC4 connector was developed. Today, the MC4 connector is the most widely used photovoltaic cable coupler in the world.

Finally, in the mid-2010s, Stäubli launched the newest member of the photovoltaic connector product portfolio: the Evo2 connector. Evo2 is designed and developed to meet the latest demands of the global photovoltaic industry and reach the highest level possible. To date, more than 314 GW of photovoltaic power generation has relied on Stäubli photovoltaic connectors-far more than any of our competitors. All major players in the photovoltaic module, MLPE and eBOS product markets rely on the safety, reliability and performance of Stäubli connector products.

Photovoltaic panels. Image source: Shutterstock.com/foxbat

Photovoltaic couplers like MC4 may be the most well-known products, but photovoltaic systems require a complete connector product portfolio, which usually includes panel mount connectors, branch connectors, cables, in-line fuses, and test plugs. Stäubli's photovoltaic cable coupler products are tested and certified to the highest international standards and requirements. This includes safety class II up to 1500 V and rated current up to 70 A. Our enclosure itself has IP65 and IP68 protection levels to provide ingress protection and beyond the scope of requirements, we also test our products against ammonia exposure and salt spray protection​​​

One of the most important aspects of all connectors is the range of contact between the plug and the socket. This is where Stäubli really shines. Thanks to our proprietary MULTILAM technology, we are able to maintain a low contact resistance of 0.25 microohms. It is also important to realize that the cable coupler itself is only part of the bag. The connector system, specified cables/sizes, appropriate tools and appropriate assembly steps determine the actual performance and safety of the product.

The cable coupler consists of metal contacts (plug/socket) and an insulator to protect them. They are usually designed for specific types of cables, cable conductor cross-sections (AWG or mm²) and cable outer diameter (OD).

Photovoltaic cables must operate in some of the most challenging environments imaginable, from the hottest day of the year to the harshest winter, to continuous ultraviolet radiation, humidity, and rapidly changing temperatures.

It is also important to consider the power level that the PV connector must be able to accommodate. In a typical 1500 V utility scale system, the connector's operating current is up to 50 A and must accommodate 75 kW of DC energy through the connector. A typical American home provides 220 V / 200 A service, which means that the connector must accommodate 44 kW of AC power. These connectors are responsible for protecting a large amount of energy and have a service life of more than 20-30 years.

Designing products to safely meet these demanding requirements requires years of experience, dedication to quality, and strict verification standards. The smallest product problems or defects, or errors in the assembly or deployment process, can have very dire consequences, including arc problems and, in some cases, fires.

One of the biggest problems we see today stems from cross-mating-the practice of plugging together two different connector products from different suppliers. There are many products that seem to be compatible, but there is no such thing as an MC4 compatible connector, and there is no certification covering installations using cross-mating practices. It also invalidates the product warranty, and perhaps most importantly, it violates the National Electrical Code.

The photovoltaic system is sold as a promise of future energy production and revenue. A poorly designed system made of low-quality or unproven components may endanger the power generation potential of the system and cause loss of profit through excessive maintenance costs.

Bankability refers to the concept that a company has a good track record of reliability, experience, and reliability. Although it is a small component, if the photovoltaic connector is not installed and maintained properly, it can cause major problems. Pre-selecting cheaper, less mature connector products may initially save money, but this may result in substantial long-term costs in terms of maintenance and downtime. When designing a system, users should always use high-quality components from the beginning.

When you have to choose between two different connector products because your cable is in the range of two different connector products, it is best to choose the connector at the top of the sealed range. The cable is suitable for both, but it is best to be at the top of the sealing range, because when you tighten the seal, it shrinks to the size of the cable. You must do this as few times as possible before it reaches the cable.

I know it is not attractive to buy different expensive crimping tools, but as we mentioned earlier, the actual photovoltaic system, tools and assembly instructions are all part of the verified system that our certification refers to. The specific tools and specific curl dye configurations we provide have been tested and verified by Stäubli and certification agencies.

If you use your own crimping tool with our products and our specified cables, we may not know what will happen, so we cannot guarantee or guarantee the tool. Our certification does not cover this situation and will have many downstream consequences because the electrical code requires you to have a certified product for its intended use.

If the connector becomes dirty, there is no proven or acceptable cleaning method. The connector uses very precise contact elements called MULTILAM. Its design is very precise, very small and complicated. Once the soil or dirt enters these areas, it is impossible to determine whether it has been completely removed. This may also contaminate the sealing surface and the O-ring itself, and the use of cleaning products may affect the electrical connection because it will coat the contacts with residue.

The best way is to take precautions and prevent the connector from getting dirty in the first place. We do provide very robust cable coupler seals, which can be reused if properly maintained. Many of our customers or installers have a box of male and female protective caps. These are used for connectors in the field and are only removed before the connectors are plugged together.

I don’t know where the rumor started, but it’s definitely not what the assembly instructions said. The assembly wrench is just a useful way to pre-tighten the nut of the cable gland. There is no way to design a plastic tool suitable for continuous use within the conditions of our PV connectors.

In fact, due to the amount of compression on the seal, the application needs to provide a specified torque for the cable gland. As with crimping tools, it is best to follow the assembly instructions and use tools that have been verified and certified for use as part of a photovoltaic system.

No, the only acceptable situation is if the two companies cooperate and their products are specifically designed to be cross-compatible, and they have passed all the testing and certification requirements, and have obtained the so-called joint compatibility certification. However, this is not currently Possibly, because this approach has many on-site problems.

Disclaimer: The views expressed here are those of the interviewees and do not necessarily represent the views of the owner and operator of this website AZoM.com Limited (T/A) AZoNetwork. This disclaimer forms part of the terms and conditions of use of this website.

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