Crimping MC4 solar connectors is easy to do. You just need a few specific tools and you can make ’em no problem.
I’ll show you how I do it with some step-by-step photos and videos.
Let’s get to it!
Materials & Tools
Materials
Note: Make sure your wire size is compatible with your connectors. Most MC4 connectors are designed for 10, 12, or 14 gauge wire.
Tools
- Wire cutters
- Wire stripper
- MC4 crimping tool (included with the MC4 connector kit linked to above)
- MC4 connector tool (included with the MC4 connector kit linked to above)
Step 1: Cut the Wire to Length
Use your wire cutters to cut your wire to length.
I decided to make my wires about 6″ (15 cm) long since I’ll be using them as short solar adapter cables for connecting my solar panel to my solar charge controller.
Step 2: Strip the Wire
Grab your wire stripper and strip your wire about 1/2″ (1.3 cm) from the end.
Repeat for as many wires as needed! I just needed two for my project.
Step 3: Crimp the Male Pin to the Wire
I’ll first show you how to crimp a female MC4 connector.
Important: The male metal pin goes with the female MC4 connector.
Insert the stripped wire into the male pin.
Place the pin’s metal fins in the jaws of your MC4 crimping tool. (Make sure all the wire strands make it inside the pin!)
Note: MC4 crimpers have different holes for different wire sizes (in mm2). Use the right hole for your wire size.
Crimp the pin to the wire by squeezing your MC4 crimper until it releases.
Tip: If your wire keeps slipping out of the pin, place the pin in the crimper and squeeze just enough until the handles lock, holding the pin in the jaws. Then insert the wire into the pin.
Test your crimp by giving the pin a good tug. The connection should hold!
Step 4: Insert the Male Pin into the Female MC4 Connector
Unscrew the end cap from the female MC4 connector. Remove it along with the compression sleeve.
Slide the end cap and compression sleeve over the pin.
Insert the male pin into the female connector until you hear a “click.” The MC4 solar connector is now connected to your wire!
Note: Double check that you’re inserting the male pin into the female connector. The connector body has a non-return clip inside — once it’s on it won’t come off!
Screw the end cap and compression sleeve on to the connector. Once you can’t screw any tighter by hand, use your MC4 connector tools to finish the job.
Make sure there’s no gap between the end cap and connector body. A tight connection will help keep water out.
Admire the thing — you’ve just crimped your first MC4 connector!
Step 5: Crimp the Female Pin to the Wire
Now we repeat the process to assemble a male MC4 connector. This time, we use the female pin.
Just like before, insert the stripped wire into the female pin.
Place the pin’s metal fins in your MC4 crimping tool.
Crimp the pin to the wire.
Give the crimp a little tug test to make sure the connection is solid.
If it’s holdin’, you’re golden! 😁
Step 6: Insert the Female Pin into the Male MC4 Connector
Unscrew the end cap from the male MC4 connector and remove it along with the compression sleeve.
Slide the end cap and compression sleeve over the pin.
Insert the female pin into the male MC4 connector until you hear a “click.”
Screw the end cap on the MC4 connector body. Once again, MC4 connector tools help a lot here!
Tighten the cap until there isn’t any gap left.
Now you know how to crimp MC4 connectors — both male and female!
Step 7: Connect & Disconnect the MC4 Solar Connectors
To connect MC4 connectors, simply push the male and female connectors together until you hear a “click.” You’ll see the male connector’s prongs latch on to the body of the female connector.
To disconnect them, squeeze the male connector’s prongs until they release from the female connector. Then pull the connectors apart.
You can also use an MC4 assembly tool to disconnect MC4 connectors. (That’s right! It’s also a disassembly tool.)
Clamp the assembly tool’s prongs over the male connector’s prongs. Then, with the tool in place, pull the connectors apart.
And that’s all there is to it!
Like I said, easy enough. 😊
