How to Correctly Crimp MC4's for Solar DC Cable

In this how-to presentation we look at the incredibly important process of crimping MC4's, from correctly mating the inserts to the connectors, tools used to cut and strip the cable through to the crimping process.
We are looking at this in relation to commercial solar systems where the voltages regularly get up to around 1000 volts and more if talking about solar farms.
Cable bending radius is discussed, correct insert seating and tightening of the MC4 nut are all shown in detail as well cable identification issues that may arise from tired solar installers!
This is perfect for the solar electrical apprentice who has never made an MC4 connection all the way to the experienced professional wanting to brush up on their technique.
Enjoy.
[Chapter]
00:00 Introduction
01:00 Inspecting the MC4s
02:00 Correct pairing on inserts and connectors
03:00 Long DC runs and correct cable selection
04:00 Stripping the cable
05:00 Making the crimp
06:00 placing the cable into the insert
07:00 Keep the strands attached
08:00 Wait until you hear the click
09:00 Careful with the inserts
10:00 High DC voltages running through the solar cable
11:00 Tightening the nut
12:00 Insert has to seat correctly
13:00 Taking the connection apart
14:00 The tools
15:00 Always check the cable
16:00 The cut test
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[@rogerbrown5563]

I've done thousands of MC4s by now - but it's good to see another bloke show how it's done. MC4 connections can not be done without correct tools. I was on a roof checking out an under-performing system - saw glowing hot wires and wisps of white smoke under a panel - cremated MC4s still burning from air draught under the panels. VERY lucky homeowner. Tafe gave us less than 5min and only one connector to practice - in the last 5 minutes of the 2 weeks of training. I've learnt SO much since then.

[@GreenwoodSolutions]

If someone says they are an expert, run the other way. Always learning. Cheers for the comment

[@RoseyCheeks07]

I have watched so many of these videos as I am a complete beginner and this was the best one! Have successfully connected my solar panels because of it. Thank you!

[@GreenwoodSolutions]

We're so happy to hear that! Best of luck on your solar journey :)

[@mikew8622]

I'm about to and 💯 agree with you! This guy is Awesome!

[@FarqueKnowsWhere]

Thanks Veli, a great detailed close up view of where to position the pin in the crimpers and how far to strip the wire back..

[@GreenwoodSolutions]

Cheers. Really tried to thing about this before we filmed but as shown at 7:25 caption wise. Yup 😃

[@schnellgelb1746]

Vendors of MC4 should link to this because it is easy to assume 2 major mistakes are O.K. The 2 mistakes are: Crimping on the insulation and inserting the male connector into the male housing ! Thanks for making it clear why this is incorrect. It will work if you make these 2 mistakes but maybe not for long and not at the rated voltage.

[@GreenwoodSolutions]

Totally agree concerning the 2 mistakes. As I always say; electricity is dangerous and should be treated with the utmost respect.

[@Electronzap]

Nice demonstration.

[@GreenwoodSolutions]

Cheers.

[@ingobulli]

This was by far the most informative video I have watched on this subject ! Great job.

[@GreenwoodSolutions]

Cheers for that. I watched quite a few MC4 videos and critiqued the absolutes out of them before we made this one.

[@AllanHolder]

thank you. i did my first mc4 connector with your help

[@GreenwoodSolutions]

That's great😃

[@AndrewSmith-yd8vy]

Mate, that's the best and correct explanation I've come across, thanks for sharing..

[@GreenwoodSolutions]

Our pleasure. Always learning and always try to do things correctly.

[@jeffottesen143]

Excellent video!! Thank you.

[@GreenwoodSolutions]

Ta for that. If you would like to see more detailed videos especially around commercial solar see www.greenwood.academy/

[@DuaneRonan]

Thank you so much for going into such great detail on how to make a good connection. There is so much bad info out there, for instance just making it hand tight, not even using the proper tools. Thank you again!

[@GreenwoodSolutions]

glad we could help!

[@ScottTurnerformeindustrious]

Very informative! Thanks for taking the time and sharing.

[@GreenwoodSolutions]

Sorry for the late reply. Our pleasure. For more see www.greenwood.academy/

[@mikew8622]

Thank You for this knowledge !

[@GreenwoodSolutions]

Our pleasure. We are really trying to show some real nitty gritty stuff when it comes to the whole solar field, especially commercial solar and if you want to become part of our Community go to www.greenwood.academy/

[@pete844]

Thanks for a super video, just fitted my first mc4 😊

[@GreenwoodSolutions]

Congratulations! We are glad to hear that :)

[@gdpower456]

clear and concise. thanks

[@GreenwoodSolutions]

We really thought how we could improve on the existing videos out there and everyday is a school day. For more specific info see www.greenwood.academy/

[@alexrobertson232]

Good work.

[@GreenwoodSolutions]

Cheers

[@andreisablinskis]

Fantastic

[@GreenwoodSolutions]

Thanks Andrei. For more detailed info see www.greenwood.academy/

[@FarqueKnowsWhere]

A question for you Veli, I want to extend solar panel wires by about a metre, do I use the exact same wire as on the panel or any same size electrical wire? Thanks

[@arthurcurry850]

I ran across MC4 connectors that just dont make that slip sound. They just keep spinning until they brake. So that sound that indicates that connector is tight enough, does it comes from connector itself OR the plastic blue tightening tool ? I thought that the connector slips a round inside the tightening tool as indication that tool doesnt have any more grip to tighten it any harder. So my question is is it bad MC4 connector or a false tightening tool ?

[@GreenwoodSolutions]

Good question. I believe it's from the tool that creates the noise at a certain torque. What will happen is that after time the tool will slip at less and less pressure so ideally the best way to test that you have tightened up the nut sufficiently is to grab the MC4 with one hand and the cable with the other and rotate. If the cable doesn't slip all is good. Some people use an aluminium tool but these are not forgiving and may result in over tightening. Hope this helps

[@Zerpersande]

I’ve got the crimper and about 6 sets of dies. No idea which one you used bc no close ups. No idea of what final crimp looks like. Again, no close ups.

[@GreenwoodSolutions]

Good point. Thinking of redoing this part at some stage. Thanks for the reminder.

[@unSTEVOED]

I Keep having problems when tightening the MC4 Nut. The Nut keeps deforming and cross threading. I never really know if I'm getting a good seal. Im guess they are just rubbish MC4s, but they are all my Electrical wholesaler stocks

[@GreenwoodSolutions]

This is a problem. Obviously use approved MC4's and chat with the wholesaler about the issue and if nothing happens there are other wholesalers . . . !

[@beaconofwierd1883]

Great video, however at 7:30 you might want to redo this part, cause there will be a fair amount of people who just follow along and do what you do and don’t see the text in the top of the video here. Doing one thing and saying another (or in this case even just typing) is not really optimal.

[@GreenwoodSolutions]

You are right. The captions should be enough but, ideally, I should have done this part of the procedure correctly but in saying that, from an Australian perspective, only A grade electricians and their apprentices are allowed to make this connection so . . . !

[@beaconofwierd1883]

@@GreenwoodSolutions Same where I live, but that doesn’t stop people from burning down their houses :p

[@alpachino468]

2:32 The female's like, 'is it in yet...?'