HRS ZH05 Series User manual

ZH05 Series
Handling Manual
COUNT
DESCRIPTION OF REVISIONS
DESIGNED
CHECKED
DATE
0
2
名称TITLE
ZH05 Series Handling Manual
APPROVED
HK.UMEHARA
20211130
CHECKED
HK.UMEHARA
20211130
DESIGNED
KH.MARUNO
20211130
WRITTEN
KH.MARUNO
20211130
技術指定書TECHICAL SPECIFICATION
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HIROSE ELECTRIC CO.,LTD.
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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..................................................................................12
7. WIRING HARNESS ASSEMBLY RECOMMENDATIONS.............................................................15
8. REPAIR PROCESS..............................................................................................................................16
9. REPAIR TOOLS....................................................................................................................................19
9.1 REPAIR TOOL FOR RETAINER........................................................................................................19
9.2 REPAIR TOOL FOR TERMINAL........................................................................................................20
10. ELECTRICAL TEST.............................................................................................................................21
10.1 CLAMPING AREAS OF CONNECTORS..........................................................................................21
10.2 LOCATION OF TEST PROBES.........................................................................................................21
10.3 DEFINITION OF TEST PROBES.......................................................................................................22
10.4 RECOMMENDATIONS FOR ELECTRICAL TESTS.......................................................................22
11. CRIMP QUALITY STANDARD...........................................................................................................23
11.1 SCOPE...................................................................................................................................................23
11.2 APPLICABLE WIRE.............................................................................................................................23
11.3 QUALITY STANDARD.........................................................................................................................23
12. CRIMP PARAMETERS........................................................................................................................25
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1. SCOPE
This harness operation manual describes the procedures for wiring, assembling and
disassembling the ZH05 connectors.
It also details the crimping information and common practices of general crimps for the ZH05
terminals.
All measurements are in millimeters and Forces in Newtons unless otherwise specified.
In addition, photographs and illustrations described are representative products of HRS
ZH05 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
【Plug】
【Receptacle】
Receptacles exist only in right angle version with DIP metal hold down.
Male housing
Retainer
Male terminal
（Crimp terminal）
Female housing
Female contact
DIP Metal hold down
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2.2 PART NUMBERS
Description
Part Number
Male terminal
ZH05-2224PCF
Plug X positions with Y coding
ZH05-XDP-HU(Y)
Receptacle X positions with Y coding
ZH05-XDS-2H(Y)
Retainer X positions
ZH05-XDP-R
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
Plug
Male housing
PA
Retainer
PBT
Receptacle
Housing
PA
Female contact
Copper alloy
Surface: Tin plating: 1µm min
Under: Nickel plating: 1µm min
Metal hold down
Brass
Surface: Tin plating: 1µm min
Under: Nickel plating: 1µm min
Male terminal
Metal thickness: 0.2±0.05 mm
Brass
Surface: Tin plating: 1µm min
Under: Copper plating: .0.3µm
min
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3. PACKAGING
Designation
HRS P/N
Carton box
dimensions
LxWxH (mm)
Type of
packaging
Quantity of parts
per unit
Receptacles
ZH05-XDS-2H
405 x 405 x 350
Reel
250 pcs/reel
5 reels/box
Plug 12P
ZH05-12DP-HU
405 x 405 x 51
Plastic
bag
100 pcs/bag
5 bags/box
Plug 16P
ZH05-16DP-HU
267 x 365 x 126
Plastic
bag
100 pcs/bag
5 bags/box
Plug 20P
ZH05-20DP-HU
360 x 270 x 130
Plastic
bag
100 pcs/bag
5 bags/box
Male
terminal
ZH05-2224PCF
560 x 570 x 250
Reel
15000 pcs/reel
5 reels/box
Retainer
ZH05-XDP-R
360 x 270 x 130
Plastic
bag
1000 pcs/bag
10 bags/box
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4. MECHANICAL PERFORMANCES
The main mechanical characteristics are as follow:
Test
Value
Tensile strength of the Wire-Terminal link
0.3mm²: 103N min
Terminal insertion force
3N max
Terminal polarization force
20N min
Terminal insertion force with TPA closed
20N min
Terminal retention force with TPA inactive
27N min
Terminal retention force with TPA active
39N min
Connector mating force
32.8N ~ 34.5N (12 terminals)
42.0N ~ 46.0N (16 terminals)
52.2N ~ 56.3N (20 terminals)
Connector unmating force
33.0N ~ 34.4N (12 terminals)
39.5N ~ 50.1N (16 terminals)
56.4N ~ 60.5N (20 terminals)
Connector retention force
150N min
Connector polarization force
100N min
Mating / unmating cycles number
30 times
TPA insertion force with all terminals fully inserted
8.7N max
TPA insertion force with one terminal incorrectly
positioned
Not possible
TPA opening force
33N min
TPA pull-out force
TPA has no preset position.
Opening and pull-out forces are
same.
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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 - Strip the cable
Please refer to the Crimp Quality Standard (§11) for details on strip length.
2 –Crimp wire in 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
1 - Insert contact and push until a click is heard.
Please take care to ensure that the terminal is inserted in the correct orientation.
Note 1: Holding the cable, please insert straight into the housing. Do not use more than 10N
of force during this process.
Note 2: If the crimped terminal does not enter the housing smoothly the first time, remove it
and then re-insert.
Upper and lower crimping portions
are inward during insertion
OK
NOT OK
Crimping portions are facing outward
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※Please hold the cable as below picture and insert it with a force less than 10 N, or terminal
will be deformed. Please use a new terminal in this case.
2 –After insertion, confirm that the terminal has been inserted correctly by pulling the cable
lightly, the pulling force must be less than 10N.
OK
NOT OK
Crimping portions are facing outward
Barrel becomes visible from outside
when cable is pulled lightly
Crimping portions are facing inward
Incorrect terminal position
Correct terminal position
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3 –Press retainer into housing until it clicks in the direction of the arrow.
Set position
After setting the retainer, please inspect the housing head-on
to confirm that the retainer is not protruding in any way.
OK NOT OK
Retainer set
OK
Retainer only half engaged
NOT OK
Confirm the retainer is visible
Correct retainer is used
Retainer part number is wrong
Connector Cross-section
Connector Cross-section
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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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8. REPAIR PROCESS
1 –Insert the special tool in direction 1 and push down the lance, and remove the retainer
from direction 2.
Note: Please refer to the next section (§9) for details on the special tool.
1
2
2
Jig □1mm max
Jig □0.6mm max
Connector cross section
Connector cross section
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2 –Insert the special tool in to the terminal cavity and push to the end with the tool flat side
up as below picture.
Maintain this position and pull the applicable cable carefully to remove the terminal.
Note: Please refer to the next section (§9) for details on the special tool.
Recommend to operate under propre illumination to enhance workability
Condition at inserted repair tool
Note: Housing is not reusable. Please use new parts after repairing.
Repair tool
Flat side
1 Insert repair tool
2 Pull cable
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Note: In case the terminal lance and / or retainer lance has been deformed, please use new
parts.
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9. REPAIR TOOLS
9.1 REPAIR TOOL FOR RETAINER
Part number summary for retainer repair tool:
Applicable part
Repair tool name
Repair tool part number
ZH05-12DP-HU
ZH05/R/RE-MD
902-5162-0
ZH05-16DP-HU
ZH05-20DP-HU
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9.2 REPAIR TOOL FOR TERMINAL
Part number summary for terminal repair tool:
Applicable part
Repair tool name
Repair tool part number
ZH05-2224PCF
ZH05/RE-MD
902-5161-0
The following drawing shows definition of tool for terminal repair.
(press fit)
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