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diy solar

Is there a better MC4 tool?

SilverFox33

SilverFox33

New Member
Joined
May 29, 2022
Messages
11
Location
Nevada City, California
Like most people's solar panels, my solar panels have MC4 connectors.

After they have been outside making power for a while, it is sometimes necessary to disconnect them for troubleshooting, new wiring configuration, upgrading and so on.

But every time I try to do that, I am so frustrated! Disconnecting cable-mounted MC4 connectors can be so hard!

Most of these are cable mount MC4 males to cable mount MC4 females. They are so stuck together!I have several MC4 removal tools. Some plastic, one metal. They are no help at all. Feels like I'm nearly ripping my shoulder muscles apart trying to disconnect a male MC4 from a female MC4. All the tools do is squeeze the two locking tabs in. This does not free up the connectors from each other at all.

Has anyone here found any MC4 tools that make this job easy?
 
If your having problems disconnecting them AND the tabs are being compressed correctly by the tool its the connectors not the tool. I have run into that on some of the cables I have bought from time to time. My solution is to cut off the connector it came with and replace it with a more user friendly one so to speak. Problem solved.

You can also change out just the plastic housing without cutting off the old ends but I usually just replace them since the tools I have make it a few seconds to do job.
 
I know it's not the intended purpose for them but I was getting pissed with the plastic mc4 tools yesterday so I went to my pliers drawer and grabbed these. They worked freaking awesome and will be my go to for any mc4 disconnections in the future.
KNIPEX Internal Snap Ring Pliers-Forged Tips https://a.co/d/gvoOFOm
I didn't use the tips like you would for a snap ring, just above the tips was the sweet spot.
 
These seem to be the hardest to disconnect. On my semi-permeant setup it is becoming an issue. Tempted to cut the outer pin cover to make like other MC4 type
 

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MC4 connectors are bloody awful IMNSHO. I've found one problem is that the plastic pins like to sieze up a little in the receptacle, then dust and dirt get behind the locaking tabs just enough. I had a couple actually break off after I cut the locking tabs trying to wiggle them free. I think a bit of lube BEFORE you connect helps, but I live in a dust pit, it's a double edged sword. I have 16 old CS panels I've re-arranged 5 or 6 times, I've replaced a dozen or so connectors. The box of 30 odd cheapo MC4's I got seems to be much more tolerant. A better design would have two o-rings with a looser fit. Instead, there should be a simple box on the back of the connector with a watertight socket for a better designed multiplex connector. I've never had a problem removing an "N" connector from an old antenna that has been baking on a roof for 30 years in the wind rain and snow, but I can't pull apart an MC4 I snapped together 5 minutes ago. Ludicrous.
 
ohmboy said:
I was going to say WD-40 but they're water proof.
Click to expand...
It helps to clean and slide the locking tabs. I sprayed it in the plastic sockets last go around, and cut the locking tabs off with a razor knife last go-round on several of the old connectors. Drives me nuts, I considered cutting the things off and wire nutting them with a baggie and a tie. If you are not moving them around I suppose it's not a huge deal.
 
I just used these to put new connectors on 28 panels and combiner box connections:

BougeRV 100PCS Solar Connector with Spanners IP67 Waterproof Solar Panel Cable Connectors Male/Female 50 Pairs(10AWG)

haisstronica Crimping Tool for Solar Connectors - AWG 14 12 10 Ratchet Wire Crimper Tool

KAOLALI Solar Panel Tester EY800W Upgraded Multimeter LCD Display MPPT Tester for Photovoltaic Panel with Power Protection and Multifunction LCD Screen

Cut off your old MC4 connectors, install the new, use dieletric grease when plugging them together. Test before plugging together with the solar multimeter.

These connectors worked great and the plastic tool used to remove them works fine. I have used many MC4 brands and never had to use anything but a plastic tool to remove. Some older MC4 connectors are out of spec, the tools don't work. Just cut them off.

This crimper works great too.

All of this from amazon.com
 
Q-Dog said:
I stuck large zip ties in those to release the pins.
Click to expand...

That seems like it would work and could be easier then a tool, plyers... Do you simply slide a zip tie into the opening and just pull the zip tie, not actually securing the zip tie. Or do you have to close and lock the zip tie, then have to cut the zip tie to remove it?
 
As I posted, many different manufacturer's of MC4 connectors are not exactly the same spec as the Staubli (which is the original, real creator of the MC4). In that case, buy some Staubli or a brand like I mentioned in the post above, cut off the old one and install a new one. Fussing around and trying to get old parts apart is a waste of time. Test new connections and use dielectric grease when plugging new connectors together.
 
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