How To
This page is dedicated to our most common how to questions from customers as they install their DIY kit or setup and use their system. We will update and add to this so check back regularly for the latest Ozark Mountain Offgrid solar how tos.
How To Assemble MC4 Connectors
Assembling MC4 connectors is not difficult if you follow a few simple guidelines. Below is an overview of the parts, tools and procedure for making quality MC4 cable connections.
1. You'll need the appropriate number and type (Male & Female) of MC4 connector kits and PV Wire (10GA is most commonly used but wire size is determined by your specific situation).
2. You'll also need wire/cable cutters, wire strippers and an MC4 crimp tool.
3. Review the length of cable run and voltage your particular system has and select the appropriate wire size for your application. Cut your cable to the appropriate length and choose the proper connector type to match up to your panel or existing cable.
4. The image below illustrates the order components are assembled on an MC4 connector
5. Using wire strippers remove approximately 3/8" of the wire jacket exposing the wire strands. Be certain you're using the correct stripping guide for the wire size being used (note in example below the 10GA wire is in the 10GA stripping guide).
6. Select the correct MC4 crimping barrel for the type of MC4 connector you are trying to make. Take note in images below; a male MC4 connector (Image A) uses the larger diameter female crimping barrel and the female MC4 connector (Image B) uses the smaller diameter male crimping barrel.
7. Place the appropriate crimping barrel into the MC4 crimping tool. Be sure to insert it in the appropriate crimping slot for your wire size on your tool. Also take note that the crimping "wings" face up towards the crimping slot that looks like an M not the side that looks like the U (see image below for reference).
8. Next twist the exposed wire strands to allow for smooth insertion in MC4 crimping barrel. Insert bare twisted wire in through the wings of barrel connector crimp until the ratcheting mechanism releases the connector. Your crimped barrel should have evenly folded wings over the bare section of wire without large bunches of excess wire strands as shown below. Give the connector and cable the tug test to be sure your crimp is secure.
9. Once crimped you can finish the assembly of your MC4 connector. First, insert the crimped barrel connector
into the MC4 connector. Its will take
a firm push to get it to fully insert
and you should hear a click or pop
when it's properly inserted. Again give the connector a tug test to ensure it's fully seated
10. Next, use the image below to reference the order of the components of the connector.
11. You can tighten the screw collar by hand, or if necessary, you can use the MC4 wrenches included in your kit to get them tight. Remember the connectors are plastic so do not over tighten!
12. You've now made your first MC4 Connector!
The process is exactly the same for making a female MC4 only using female connector components.
Using MC4 Wrenches
MC4 wrenches are usually included in crimping kits and are sometimes included with connectors. While they aren't necessary, they may make it easier for those with hand weakness, arthritis, neuropathy or other conditions that impact hand strength or dexterity. This is a quick overview of their uses.
Tightening MC4 collars during assembly
Place the male or female end of the connector into one wrench using the hole that best secures it.
Take your second wrench and and place the C shaped opening over the screw collar then twist each wrench in opposite directions to tighten.
Wrenches can also be used to take apart male and female connectors that have been connected to each other.
Simply use the two prongs on either the face or end of the wrench to depress the locking clips on the male connector and pull the two connectors apart.
Using wrenches face prongs to separate MC4 connectors
Using the wrenches end prongs to separate MC4 connectors