Among these was the fact that the system had two sets of cables and wires, which led to considerable annoyance in the field when equipment from different vendors could not be plugged together. Tyco's Solarlok became a market leader for a period in the late 2000s, but a number of factors conspired to push it from the market. Later, the MC4 PV connector, launched in 2004, provided these positive locking mechanisms, leading to widespread market acceptance. The MC3 PV connector lacked these requirements. Two US-based companies, Tyco Electronics and Multi-Contact (purchased by Staubli in 2002), responded by introducing new connectors to meet this requirement. Radox, a European manufacturer, did not respond to this specification and has since disappeared from the market. PV connectors were required to contain positive locking mechanisms controlled by certified, product specific tools. In 2008, the NEC banned the opening of PV connectors under load. Two connectors became somewhat common during this period, the Radox connector and MC3 connector, both of which essentially looked like weather-sealed phono jacks. The cables ended with PV connectors that met the definition of a convenience receptacle, meaning they could be (legally) connected together by anyone.
In these systems, the junction box was sealed and two wires were permanently attached using strain reliefs. Starting in the 2000s, a number of companies introduced products to address these issues. Additionally, these sorts of connections were subject to problems caused by water leakage, electrical corrosion and mechanical stress on the wires. Above 50V only a licensed electrician can make the connections.
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However, in the USA, bare terminals of this sort are limited to 50 V or less by the National Electrical Code (NEC). In the past, this was accomplished by opening a small electrical box on the back of the panel and connecting user-supplied wires to screw terminals within.
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While small solar panels used for battery charging and similar tasks may not require special connectors, larger systems normally connect the panels together in series to form strings. MC4 name stood for Multi-Contact and its size 4mm PV connectors, introduced by Multi-Contact in 2004. The MC3 connectors were discontinued in 2016.
MC3 had certification ratings of (1000VIEC/600V UL) and 30A (10AWG PV Cable). MC3 is the abbreviation of Multi-Contact and its size 3mm PV connector with 3 mm contact pin.
MC4 connectors are successors of the MC3 Connectors, which were developed by Multi-Contact in 1996. Originally rated for 600V, newer versions of the MC4 connector are rated at 1500V, which allows longer series strings to be created. In addition, IEC 62548 ‘design requirements for PV Systems' require PV connectors to be of the same origin. The National Electric Code (NEC) and the UL6703 standard for PV connectors specify that connectors have to be from the same type and brand to avoid the dangers of cross-mating. MC4s allow strings of panels to be easily constructed by pushing the compatible connectors from adjacent panels together by hand, but require a tool to disconnect them to ensure they do not accidentally disconnect when the cables are pulled. The MC in MC4 stands for the manufacturer Multi-Contact (now Stäubli Electrical Connectors) and the 4 for the 4 mm diameter contact pin. MC4 connectors are single-contact electrical connectors commonly used for connecting solar panels.
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