Business Unit

Technology Newsletter

PV Power
Dangers of using
counterfeit connectors

Photovoltaics
Australia
Dangers of using Dangers of using
counterfeit connectors counterfeit connectors

PV Connectors are one of the most critical The biggest loser in all of this is the home TUV state3 A growing number of suspect copies
parts of an installation in regards to owner who has paid many thousands of Compatibility of PV-Connectors can be of Multi-Contact’s world renowned
safety, and yet they are often overlooked dollars for a solar installation and ended up currently confirmed only for products of the MC Solar components have recently
compromising the performance of the with an inferior, and potentially dangerous, same series from the same manufacturer. appeared on the market. Comparative
array and putting the home owners product on their roof. measurements and material tests have
safety at risk. Don’t Risk It. revealed substantial deficiencies in
The manufacturer of the connector is quality, and compromised safety and
The wrong connector or the miss-mating of very important: If this advice is ignored, then the installation system performance.
different brands can cause high resistance does not meet CEC/ORER requirements, and How can you recognise the genuine products?
connections or allow water ingress which Clean Energy Council guidelines state1 it will not follow manufacturers guidelines, Visually, the copies are virtually indistinguishable
can result in premature failure of the array Only connectors which are the same type/ leaving full responsibility for any failure of from the genuine MC products. Multi-Contact Using copies mated with the genuine Multi- Inferior copies can be disastrous, potentially
and possibly fire. model from the same manufacturer are the connectors on the installer, unless the is defending itself on the one hand by taking Contact connectors can result in a poor fit resulting in overheated connectors and
allowed to be married at a connection installer has been deceived by misleading court action against the imitators and on between insulator parts that can result in cables which has dangerous consequences.
The term MC4 stands for Multi-Contact 4mm point. supply of counterfeit product. the other hand by increasing awareness to system failure due to compromised sealing As an installer or OEM, you guarantee your
system (MC3 stands for Multi-Contact 3mm protect you and your customers from the against the elements such as rain or dust. system for 20 years or more, therefore
system), but unfortunately there are some In the Conditions of Acceptability Excerpt from CEC Code of Conduct4 financial and reputational damage that can As a result, the insulating properties are no don’t risk it, for the sake of saving a few
unscrupulous companies in Australia selling (C of A) section from UL, the following All persons holding any form of Clean Energy result from the use of inferior products. longer assured and a person touching the cents in the overall cost of an installation,
counterfeit connectors and calling them MC4. statement has been added2 Council Accreditation: shall solicit work, Concerns have been highlighted about the connector may be electrocuted. always ask for, and demand the genuine
It is sometimes hard to tell the difference These devices have only been assessed for advertise and promote their services and safety characteristics such as UV-resistance, Multi-Contact MC connector.
between these copies and the genuine UL Recognition with specific types of mated products with dignity and truth, avoiding contact resistance, and material quality, For your safety, we do not recommend using
product. Legitimate connector companies connectors within their product family. They any potentially misleading statements or that may be dangerous when installed in inferior copies, as the mating forces, plating If you have any concerns about the authenticity
use their own branding on their connectors, have not been assessed to operate with omissions. a PV system. materials and insulation properties cannot of the product you are currently using or
and yet some “unknown” manufacturers any other similar devices from any other be guaranteed. Effects such as fretting being supplied, please contact Multi-Contact’s
hide behind other people’s brands. manufacturer. The serious problems which result from corrosion may be caused by incompatible partner in Australia, DKSH, on 1800 010 113
inadequate compatibility or the use of plating materials, contact forces and other to confirm if the product you are using is a
Pros and Cons from different perspectives of using counterfeit product on a solar installation: influences. In order to avoid such adverse
inferior copies frequently occur only after a genuine MC connector.
Perspective of: Pros Cons considerable period of time has elapsed. The effects, the contacts and insulating parts
Importer of Usually looking for short term gains and not considering the Breaches CEC Code of Conduct4. use of poorly matched connectors can cause of the connectors must have compatible MC3 MC4
counterfeits implications on installer, home owner, or solar industry. Risks court action for breaches of Trade Practices Act. contact problems that can directly or indirectly properties. Tests of such properties are
Wholesaler May save a very small amount of money, and may or may not pass on Risks court action for breach of copyright and misleading behaviour.
lead to a marked rise in the temperature of time-consuming and are not covered by
the savings to the installer. May have to compensate installer for rework, if system fails
Installer May save $2 on an installation that the client has paid many Risks livelihood and peoples lives if connector fails. the plug connector due to a higher contact certification tests.
thousands of dollars for. May have to spend time reworking job if it doesn’t work first time. resistance. This can subsequently result in
Home owner None Shorter system life. arcing and ultimately to a fire. This can lead Multi-Contact has been involved in the
Possible fire and loss of property or life.
to substantial damage to your professional solar industry with their high quality
reputation, loss of revenue from the PV plug connector systems for photovoltaic
Below is a table of brand names and manufacturers of these connectors. Some manufacturers are unknown, as the companies selling
system, material damage, and quite possibly installations for more than 10 years, and
them do not disclose the manufacturer of the connector. Others use the MC4 name to deceive the installer into thinking they are
personal injury. has gained considerable experience on
purchasing Multi-Contact. It is advised that you ask for the manufacturers name (in writing) so that you are covered in case of failure.
the long-term behavior of millions of plug A temperature increase test by the TÜV
connectors. Rheinland with PV plug connectors from
Unknown manufacturer of Huber +
various manufacturers shows significant
Manufacturer Multi-Contact Lapp Wieland Amphenol Wiedmuller Lumberg LTW copied connectors TYCO Suhner
differences in the rise in temperature and
Brand MC4 Epic Solar 4 PST40 H4 WM4 LC4 SC4 MC4 PV4 CN40 Solarlok Radox the excellent results of MC-PV connectors.
1
Grid Connect Install and Supervise Guidelines (CEC) Issue 6 September 2010
2
UL File # E181720
3
See page 5 of this document
4
Clean Energy Council Code of Conduct

2 DKSH Australia Pty. Ltd., 14-17 Dansu Court, Hallam VIC 3803, Australia. Freecall 1800 010 113, Fax (03) 9554 6677, www.dksh.com.au/pvpower DKSH Australia Pty. Ltd., 14-17 Dansu Court, Hallam VIC 3803, Australia. Freecall 1800 010 113, Fax (03) 9554 6677, www.dksh.com.au/pvpower 3
Connectivity for Connectivity for
PV-connectors PV-connectors

In connection with developments in
the PV sector, a growing number of
competitors have brought PV plug
connectors claimed to be “compatible
for mating with MC” onto the market.
Some of these competitors use “TÜV
certificates” of mating compatibility with
MC connectors as a sales argument. In this
regard, the following should be noted: To
our knowledge, these in no way constitute
a TÜV certification of the mating of non-
MC products with MC products. They
relate only to a selection of tests from
those prescribed by the standard which
have been carried out by TÜV at the
request of our competitors. The results
of such neutral test reports certify only
that only various tests selected from the
standard showed no deviations from the
norm.
Test reports of this kind confer no right to bear
a GS symbol or other mark of compliance.
In detail, such TÜV documents as are known
to us include only the results of a number of
short-time tests from the test standards. All
long-time tests such as Accelerated Ageing
are systematically omitted. Water-tightness
tests have been only partially carried out,
and we are not aware of any complete IP65
test having been performed. Nor is there
any long-term field experience with such
combinations of MC and non-MC products.
To sum up, it can be categorically stated
that such documents do not constitute
“TÜV certification” of the mating of other
makers’ products with MC products.
For safety and liability reasons, MC does
not itself recognise the compatibility of
products advertised by competitors as
MC-compatible.
The different tolerance ranges in the
products of different manufacturers
is already sufficient reason for MC to
accept no responsibility whatever for
such mating combinations. Furthermore,
in our view there is no assurance that
the contact forces between the live parts
of MC and other makers’ products are
durably maintained. Nor has the chemical
compatibility of the different materials and
auxiliary substances used in production
been proved beyond all doubt.
MC has been in the market with PV plug
connector systems for more than 15 years,
and has experience with the long-term
behaviour of millions of plug connections. The
various characteristics of plug connections are
simultaneously recorded in test installations,
thus providing dependable evidence of their
good long-term behaviour.
For the reasons stated above, no such
certainty exists in a combination of MC
and other products. MC still recognises no
statements by other manufacturers regarding
the mating compatibility of their products
with those of MC.
Dr. Joachim Hirmke
Division Manager
Photovoltaics
Multi-Contact Essen

Many of today‘s patents are evidence of

MC‘s innovative engineering knowledge
Copied MC-Connector after 1,000 hours and the ability to translate this into market-
Damp heat test at 85°C. oriented products

4 DKSH Australia Pty. Ltd., 14-17 Dansu Court, Hallam VIC 3803, Australia. Freecall 1800 010 113, Fax (03) 9554 6677, www.dksh.com.au/pvpower DKSH Australia Pty. Ltd., 14-17 Dansu Court, Hallam VIC 3803, Australia. Freecall 1800 010 113, Fax (03) 9554 6677, www.dksh.com.au/pvpower 5

Toughness test for
PV plug connectors
Multi-Contact subjects PV connectors
to extremely rugged tests. For this
purpose the test laboratory in Allschwil
has been enlarged and equipped with
state-of-the-art climatic exposure test
cabinets.
Components for PV connectors are
manufactured at various sites in Switzerland
and abroad. The injection moulding tools
used must be approved by Multi-Contact
for the production of these parts.
If a tool is replaced, new testing is immediately
carried out. Identical qualitative characteristics
and exact compliance in form and the
properties of the material are an essential
requirement for the compatibility of the
individual components and thus for the correct
function of the finished plug connectors.
The test laboratory in Allschwil has been
enlarged and equipped with modern climate
cabinets.
6 DKSH Australia Pty. Ltd., 14-17 Dansu Court, Hallam VIC 3803, Australia. Freecall 1800 010 113, Fax (03) 9554 6677, www.dksh.com.au/pvpower
In order to better supervise this important
process and to save time, MC decided to
expand the test laboratory and carry out
the tests itself. What tests are needed,
and on what scale, is determined by the
various PV standards.
The tests are recorded digitally and the
results for the individual assemblies and
test sequences set down in a test report.
In the climatic shock cabinet, specimens
are exposed to extreme temperature
variations from -40°C to +85°. They are
then subjected to a visual assessment
and the functionality of the plugs is
checked. If these tests are passed, they are
followed by a 1000-hour moist heat test
at 85% atmospheric humidity and 85°C.
Connections with different cable types are
tested in a single batch.
In the moist heat test the specimens are
subjected to an atmospheric humidity of
85% at an ambient temperature of 85°C.
COUNTERFEIT CONNECTOR WARNING
If it’s not Multi-Contact,
it’s not MC4
A growing number of suspect copies of Multi-Contact’s MC4 Solar components have
recently appeared on the market. Stringent testing* has revealed substantial deficiencies
An IP test in an immersion tank shows in quality resulting in compromised safety and impaired system performance.
whether the connection is watertight.
Further electrical tests are carried out
in order to determine the safety of the
plug connectors, as well as a strain relief
ORIGINAL MC4
test and a torsion test (twistingoff of the MADE IN SWITZERLAND
cable). The connector is not released for
MC LOGO BLACK O-RING
production until it has satisfactorily passed
all these tests.
GENUINE MC PROVEN QUALITY FULLY TESTED RELIABLE
COPY
MADE WHERE?
NO MC LOGO RED O-RING
INFERIOR COPY INFERIOR QUALITY CAN BE DISASTROUS RISK TO WARRANTIES
Why would you risk it for the cost of just a few cents more?
Ask for the name you can trust, demand genuine MC4 connectors.
The preliminary test in the upper part of
the cabinet has a duration of 400 hours.
After function tests have been passed, this
is followed by 600 hours in the lower part.
* A temperature increase test by the TÜV Rheinland with copied PV connectors from various manufacturers showed significant differences in higher temperature.
This was in stark contrast to the excellent results of the MC4 -PV connectors.
DKSH Australia Pty. Ltd., 14-17 Dansu Court, Hallam VIC 3803, Australia. Freecall 1800 010 113, Fax (03) 9554 6677, www.dksh.com.au/pvpower 7
MC4 Features Multilam Technology

Features:
Protected Salt mist spray test
• Minimal contact resistance
UV IP67 • Minimal voltage drop
Safety class II IEC 60068-2-52 • Allows high specific current density
• Large number of contact points
Proven Multilam • Self-cleaning in contact area
technology with high Compatibility • Minimal power loss
long-term stability
MC4PLUS MC4QUICK

MC4 Benefits:
• Minimal heat build-up
• Energy savings
More than 40 years MC4 • Lower material costs
of experience and MC4PLUS MC4QUICK
core competence
• High specific current capacity
• Low maintenance costs
• Perfect function over thousands of
Range of cable Certificates
mating operations
cross-sections
TÜV • Longer product life
10mm 2

UL
6mm2 10AWG recognised An ingenious idea: Better contacts: Advantages:
4mm 2 12AWG The success story of Multi Contact is based The MC Multilam brought substantial The Multilam soon developed into a whole
GOST-R
2,5mm2 14AWG on the development of specially formed improvements in relation to conventional system of contact elements. Its users recognised
16AWG
1,5mm2
hard copper strips for electrical contact, the contact systems. its outstanding advantages and within a
so-called MC Multilams. short time a wide range of new application
Locking system Safety locking device possibilities had evolved.
NEC 2011

The Multilam Principle:

The louver contacts are produced from strips, Each louver forms an independent, spring Above: Contact arrangement with torsion
and allow electrical contact to be made via loaded current bridge, so that the many spring-type Multilam.
a large number of defined, current carrying parallel louvers substantially reduce the
contact points. overall contact resistance.

8 DKSH Australia Pty. Ltd., 14-17 Dansu Court, Hallam VIC 3803, Australia. Freecall 1800 010 113, Fax (03) 9554 6677, www.dksh.com.au/pvpower DKSH Australia Pty. Ltd., 14-17 Dansu Court, Hallam VIC 3803, Australia. Freecall 1800 010 113, Fax (03) 9554 6677, www.dksh.com.au/pvpower 9
MC3 Connectors MC4 Connectors

MC3 Connector System MC4 Connector System

IP67, 1000V DC, 30A IP67, 1000V DC, 30A

Female cable coupler Female cable coupler Female panel receptacle

Type PV-KBT3 II Type PV-KBT3/6III Type PV-ADBP3/GWD Female cable coupler Female cable coupler Female panel receptacle
Part number 32.0002 Part number 32.0006 Part number 32.0052 Type PV-KBT4/2.5 I Type PV-KBT4/6 II 2.5mm2 conductor 32.0054P0001
Conductor size (mm²) 2-4 Conductor size (mm²) 6 Conductor size (mm²) 2-4 Part number 32.0010P0001 Part number 32.0016P0001 4-6mm2 conductor 32.0056P0001
Cable OD (mm) 4.9 - 7.1 Cable OD (mm) 6.5 - 9 Conductor size (mm²) 1.5 - 2.5 Conductor size (mm²) 4-6
Cable OD (mm) 3-6 Cable OD (mm) 5.5 - 9

Male cable coupler Male cable coupler Male panel receptacle

Type PV-KST3 II Type PV-KST3/6III Type PV-ADSP3/GWD Male cable coupler Male cable coupler Male panel receptacle
Part number 32.0003 Part number 32.0007 Part number 32.0053 Type PV-KST4/2.5 I Type PV-KST4/6 II 2.5mm2 conductor 32.0055P0001
Conductor size (mm²) 2-4 Conductor size (mm²) 6 Conductor size (mm²) 2-4 Part number 32.0011P0001 Part number 32.0017P0001 4-6mm2 conductor 32.0057P0001
Cable OD (mm) 4.9 - 7.1 Cable OD (mm) 6.5 - 9 Conductor size (mm²) 1.5 - 2.5 Conductor size (mm²) 4-6
Cable OD (mm) 3-6 Cable OD (mm) 5.5 - 9

Branch socket Branch plug MC3 sealing caps

Branch socket Branch plug MC4 sealing caps
Type PV-AZB3 Type PV-AZS3 Suits female 32.0720
Part number 32.0008 Part number 32.0009 Suits male 32.0721 Type PV-AZB4 Type PV-AZS4 Suits female 32.0716
Part number 32.0018 Part number 32.0019 Suits male 32.0717

Preassembled leads
Our preassembled leads are made with
high quality Lapp ÖLFLEX® Solar XLS cable
fitted with male and female Multi-Contact Preassembled leads 2.5mm² leads 4mm² leads 6mm² leads
Preassembled leads 2.5mm² leads 4mm² leads 6mm² leads
2 metre XPMC3SOL2.5/2M XPMC3SOL4/2M XPMC3SOL6/2M
connectors. Custom lengths and variations 2 metre XPMC4SOL2.5/2M XPMC4SOL4/2M XPMC4SOL6/2M
5 metre XPMC3SOL2.5/5M XPMC3SOL4/5M XPMC3SOL6/5M
on plug options can be manufactured 5 metre XPMC4SOL2.5/5M XPMC4SOL4/5M XPMC4SOL6/5M
8 metre XPMC3SOL2.5/8M XPMC3SOL4/8M XPMC3SOL6/8M
upon request. Leads manufactured with 8 metre XPMC4SOL2.5/8M XPMC4SOL4/8M XPMC4SOL6/8M
10 metre XPMC3SOL2.5/10M XPMC3SOL4/10M XPMC3SOL6/10M
10 metre XPMC4SOL2.5/10M XPMC4SOL4/10M XPMC4SOL6/10M
Multi-Contact FlexSol XL cable are also 12 metre XPMC3SOL2.5/12M XPMC3SOL4/12M XPMC3SOL6/12M
12 metre XPMC4SOL2.5/12M XPMC4SOL4/12M XPMC4SOL6/12M
available. 15 metre XPMC3SOL2.5/15M XPMC3SOL4/15M XPMC3SOL6/15M
15 metre XPMC4SOL2.5/15M XPMC4SOL4/15M XPMC4SOL6/15M

Tooling
Crimp tool and assembly tool required to 2.5mm2 Connector body & contacts (2000 pcs)
assemble MC3 connectors. Female cable coupler 32.0010P2000
Male cable coupler 32.0011P2000
4-6mm2 Connector body & contacts (2000 pcs)
Field assembly tool Crimp tool Female cable coupler 32.0016P2000 MC4 crimp tool Open end spanner (pair)
PV-RWZ3 32.6050 PV-CZ 32.6008 Male cable coupler 32.0017P2000 PV-CZM19100A 32.6020.19100 PV-MS 32.6024

10 DKSH Australia Pty. Ltd., 14-17 Dansu Court, Hallam VIC 3803, Australia. Freecall 1800 010 113, Fax (03) 9554 6677, www.dksh.com.au/pvpower DKSH Australia Pty. Ltd., 14-17 Dansu Court, Hallam VIC 3803, Australia. Freecall 1800 010 113, Fax (03) 9554 6677, www.dksh.com.au/pvpower 11
MC3 Connectors MC3 Connectors
TÜV Certification TÜV Certification

12 DKSH Australia Pty. Ltd., 14-17 Dansu Court, Hallam VIC 3803, Australia. Freecall 1800 010 113, Fax (03) 9554 6677, www.dksh.com.au/pvpower DKSH Australia Pty. Ltd., 14-17 Dansu Court, Hallam VIC 3803, Australia. Freecall 1800 010 113, Fax (03) 9554 6677, www.dksh.com.au/pvpower 13
MC4 Connectors MC4 Connectors
TÜV Certification TÜV Certification

14 DKSH Australia Pty. Ltd., 14-17 Dansu Court, Hallam VIC 3803, Australia. Freecall 1800 010 113, Fax (03) 9554 6677, www.dksh.com.au/pvpower DKSH Australia Pty. Ltd., 14-17 Dansu Court, Hallam VIC 3803, Australia. Freecall 1800 010 113, Fax (03) 9554 6677, www.dksh.com.au/pvpower 15
DKSH Australia Pty. Ltd. Customer Service: 1800 010 113 Fax: (03) 9554 6677
14-17 Dansu Court, Hallam VIC 3803, Australia S.A. Customers: (08) 8440 1300 Fax: (08) 8241 5134
www.dksh.com.au/pvpower W.A. Customers: (08) 6254 5900 Fax: (08) 9277 8755