HRS ZE064W Series User manual

ZE064W Series
Handling Manual
COUNT
DESCRIPTION OF REVISIONS
DESIGNED
CHECKED
DATE
0
TITLE
ZE064W SERIES HANDLING MANUAL
APPROVED
HK.UMEHARA
20220209
CHECKED
HH.TSUKUMO
20220209
DESIGNED
TY.MOGI
20220209
WRITTEN
TY.MOGI
20220209
TECHICAL SPECIFICATION
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FORM HC0011-9-1
HIROSE ELECTRIC CO.,LTD.
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FORM HC0011-9-2
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TABLE OF CONTENTS
1. SCOPE.....................................................................................................................................................3
2. PARTS DESCRIPTION .........................................................................................................................4
2.1 DESCRIPTION........................................................................................................................................4
2.2 PART NUMBERS ...................................................................................................................................5
2.3 MATERIALS ............................................................................................................................................6
3. PACKAGING ...........................................................................................................................................7
4. MECHANICAL PERFORMANCES ......................................................................................................8
5. STORAGE - HANDLING OF COMPONENTS ...................................................................................9
5.1 STORAGE CONDITIONS .....................................................................................................................9
5.2 HANDLING OF COMPONENTS..........................................................................................................9
6. ASSEMBLY PROCESS.......................................................................................................................11
6.1 CRIMPING OF TERMINALS...............................................................................................................11
6.2 CONNECTOR ASSEMBLY INSTRUCTIONS..................................................................................13
7. WIRING HARNESS ASSEMBLY RECOMMENDATIONS.............................................................20
8. ASSEMBLY PROCESS TO THE PANEL .........................................................................................21
9. MATING OPERATING PROCESS ....................................................................................................24
10. REPAIR PROCESS..............................................................................................................................26
11. REPAIR TOOLS....................................................................................................................................30
11.1 REPAIR TOOL FOR RETAINER........................................................................................................30
11.2 REPAIR TOOL FOR TERMINAL........................................................................................................31
12. ELECTRICAL TEST.............................................................................................................................33
12.1 CLAMPING AREAS OF CONNECTORS..........................................................................................33
12.2 LOCATION OF TEST PROBES.........................................................................................................34
12.3 DEFINITION OF TEST PROBES.......................................................................................................35
12.4 RECOMMENDATIONS FOR ELECTRICAL TESTS.......................................................................36
13. CRIMP QUALITY STANDARD...........................................................................................................37
13.1 SCOPE...................................................................................................................................................37
13.2 APPLICABLE WIRE.............................................................................................................................37
13.3 QUALITY STANDARD.........................................................................................................................37
14. CRIMP PARAMETERS........................................................................................................................40
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1. SCOPE
This harness operation manual describes the procedures for wiring, assembling and
disassembling the ZE064W connectors.
It also details the crimping information and common practices of general crimps for the
ZE064 terminals.
All measurements are in millimeters and Forces in Newtons unless otherwise specified.
In addition, photographs and illustrations described are representative products of HRS
ZE064W series, so they differ depending on products.
Information of this manual is subject to change without notices.
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2. PARTS DESCRIPTION
2.1 DESCRIPTION
【Male connector】
【Female connector】
Female housing
Retainer
Female terminal
（Crimp terminal）
Housing seal
Wire seal
Seal cover
Plug
Male housing
Male terminal
（Crimp terminal）
Collar
Retainer
Panel seal
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2.2 PART NUMBERS
Description
Part Number
Male terminal
ZE064-2022PCF
Female terminal
ZE064-2022SCF
Female connector X positions (coding A or B)
ZE064W-XDS-HU/R(Y)
Male connector X positions (coding A or B)
ZE064W-XDP-HU/R(Y)
Plug
ZE064W-WCP(2022)
Note 1: please check with Hirose Sales department for the availability of all part numbers.
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2.3 MATERIALS
Part
Sub part
Material
Female connector
Female housing
PA
Retainer
PA
Housing seal
Silicone
Wire seal
Silicone
Seal cover
PBT
Male connector
Housing
PA
Retainer
PA
Panel seal
Silicone
Collar
Carbon steel
Surface: Nickel plating:
5µm min
Female terminal
Metal thickness: 0.2±0.05 mm
Copper alloy
Surface: Tin plating: 1µm min
Under: Copper plating: .0.3µm
min
Male terminal
Metal thickness: 0.2±0.05 mm
Copper alloy
Surface: Tin plating: 1µm min
Under: Copper plating: .0.3µm
min
Plug
PBT
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3. PACKAGING
Designation
HRS P/N
Carton box
dimensions
LxWxH (mm)
Type of
packaging
Quantity of parts
per unit
Female
connector
8P
ZE064W-8DS-HU/R
(A) or (B)
495 x 315 x 200
Tray
120 pcs/tray
x 5 layers
= 600 pcs
Female
connector
14P
ZE064W-14DS-HU/R
(A) or (B)
495 x 315 x 200
Tray
96 pcs/tray
x 5 layers
= 480 pcs
Female
connector
24P
ZE064W-24DS-HU/R
(A) or (B)
495 x 315 x 200
Tray
55 pcs/tray
x 5 layers
= 275 pcs
Male
connector
8P
ZE064W-8DP-HU/R
(A) or (B)
495 x 315 x 200
Tray
70 pcs/tray
x 5 layers
= 350 pcs
Male
connector
14P
ZE064W-14DP-HU/R
(A) or (B)
495 x 315 x 200
Tray
60 pcs/tray
x 5 layers
= 300 pcs
Male
connector
24P
ZE064W-24DP-HU/R
(A) or (B)
495 x 315 x 200
Tray
50 pcs/tray
x 5 layers
= 250 pcs
Male
terminal
ZE064-2022PCF
570 x 570 x 55
Reel
15000 pcs/reel
Female
terminal
ZE064-2022SCF
570 x 570 x 55
Reel
13000 pcs/reel
Plug
ZE064W-WCP(2022)
According number
of plugs to be sent
Bag
1000 pcs/bag
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4. MECHANICAL PERFORMANCES
The main mechanical characteristics are as follow:
Test
Value
Tensile strength of the Wire-Terminal link
AWG20: 70N min
AWG22: 50N min
Terminal insertion force
4N max for female terminals
3N max for male terminals
Terminal polarization force
9N min for female terminals
30N min for male terminals
Terminal retention force with TPA inactive
25N min
Terminal retention force with TPA active
85N min for female terminals
86N min for male terminals
Connector mating force
27.5N ~ 31.3N (8 terminals)
44.3N ~ 48.0N (14 terminals)
78.4N ~ 85.0N (24 terminals)
Connector unmating force
15.0N ~ 22.4N (8 terminals)
34.0N ~ 40.4N (14 terminals)
50.0N ~ 55.5N (24 terminals)
Connector retention force
230N min
Connector polarization force
150N min
Mating / unmating cycles number
30 times
TPA insertion force with all terminals fully inserted
20N max
TPA insertion force with one terminal incorrectly
positioned
70N min
TPA opening force
10N min
TPA pull-out force
10N min
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5. STORAGE - HANDLING OF COMPONENTS
5.1 STORAGE CONDITIONS
Store in a well ventilated environment with the following relative temperature and
humidity range: -10° to 60°C ; 85% HR maximum.
Store without contact with the ground, on a pallet or platform, a clean dry surface
until the packages are retrieved for production.
Store packages away from water and direct UV rays.
Store packages away from heat and areas with high temperature variations.
Keep away from high temperature or hygrometry variations to avoid
condensation inside the packages.
Store packages away from dust to keep the components clean.
Keep packages as they are delivered, without undoing the adhesive ribbon until
use.
Do not walk or place heavy objects on packages.
Where packages are stored in racks, place the heavier cartons below and the
lighter ones above not to damage the parts.
5.2 HANDLING OF COMPONENTS
Do not touch the terminal contact points or the interior of the barrel.
In the event that the terminal must be handled, please wear gloves in order to
prevent corrosion.
Placing items on top of a terminal or dropping a terminal may result in shape
deformities or contamination. Please handle terminals with care.
In the event of terminals becoming tangled, please do not forcibly pull or bend
them apart, but disentangle them carefully.
Use caution when handling terminals so as to avoid deformation.
Make sure that the terminals of crimped cables do not become entangled. When
bundling or stacking cables, please prevent the terminals from being subjected to
any external force.
Use caution to ensure that the part is not subjected to any large impacts.
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Do not place wire harnesses on the floor.
Refrain from any handling that may result in terminal damage or deformation.
Do not use the housing in case it drops.
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6. ASSEMBLY PROCESS
6.1 CRIMPING OF TERMINALS
1 –Cut the cable
Set the cable length with reference to the dimensions shown below.
Approximate cable cut length = above cable length + 7mm
2 - Strip the cable
Please refer to the Crimp Quality Standard (§11) for details on strip length.
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3 –Crimp wire in terminal
Male terminal:
Female terminal:
Note 1: Please use the Hirose crimp tool.
Note 2: Please refer to the Crimp Quality Standard (§11) to confirm terminal compatibility
and check crimp condition.
Note 3: Please refer to the Crimp parameters (§12) for the crimp parameters to be used.
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6.2 CONNECTOR ASSEMBLY INSTRUCTIONS
Male connector:
1 –Pick a connector from the tray.
Please hold connectors except panel seal part.
And also be careful that the oil of the panel seal not to be touched with other objects except
connector housing and retainer.
Plastic board
Tray
Cardboard box
PP band
Panel seal (red)
Housing
(black or grey)
Retainer (white)
Collar (silver)
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2 - Insert the terminal straight to the housing (refer to below direction) until a click by the
lance is heard.
The terminal is inserted with the
crimping portion facing upward.
Supplementary figure of terminal
insertion direction
Terminal No.1
Retainer wide side
Retainer wide side
Retainer narrow side
The crimping portion
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3 –Push the pre-set retainer from wide side until it clicks.
Please don’t touch the panel seal more than necessary.
After setting the retainer, please make sure the retainer is not inclined as seen from the front.
If it is tilted, push in an additional retainer to make it set.
*Set condition of retainer *One side of the retainer not installed.
(Even in the case of this left-right reversal.)
OK NG
Retainer wide side
Retainer tilting
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4 –Please protect the panel seal not to be touched with other objects.
The protector is required not to be deformed excessively during packaging, shipping and
being stored.
e.x.) Cover the whole part of connector with plastic cup and tighten the cables to hold.
Tighten to hold
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Female connector:
Note: Hold the cable and insert it straight.
At both the upper row and the
lower, the terminal is inserted with
the crimping portion facing upward.
The terminal is inserted with crimping
portion facing downward.
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2 –Push the pre-set retainer until it clicks.
Please use a dedicated tool for the set of retainer.
Dedicated tool can be substituted as long as the following dimensions (Plastic recommended).
Push the dedicated tool
in the direction indicated by the arrow.
Tool dimensions:
Dedicated tool
Dedicated tool
Retainer
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Set condition of retainer
After setting the retainer,
please make sure the retainer is not inclined as seen from the front.
*Set condition of retainer *One side of the retainer not installed.
(Even in the case of this left-right reversal.)
OK NG
In case of cavities where terminals are not inserted, please use plugs to ensure
waterproofness of connectors.
Below dimension should be respected to ensure correct position of plugs:
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7. WIRING HARNESS ASSEMBLY RECOMMENDATIONS
Deformed or damaged parts have to be replaced by a new one.
Apply tape so that every individual wire is subjected to an equal amount of tensile
force to avoid any effect on terminals (like disengagement).
The distance to apply tape from the end of connector is 35mm minimum.
The bending radius for wires should be at minimum 3 times its outer radius to
ensure normal use of our connectors.
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