ZERUN Z4S-abcde Series User manual

ZE
R
DC
P
Conn
INSTR
R
UNZ
P
hoto
v
ection
S
UCTIO
N
4Sab
c
v
oltai
c
S
y
stem
f
N
MAN
U
c
deSe
c
Conn
e
f
or Sola
r
U
AL
ries
e
ctor

r
Panel

Rev. A

INSTRUCTION MANUAL
Rev. A
Dongguan Zerun Electronics Technolog
y
Co.,Ltd.
( NO.1 Xianxi Industrial Park, Zhen‘an Road, Shangjiao, Chang’an Dongguan, Guangdon, P.R. China )
1 / 9
Content
1.Scope......................................................................................................................................................2
2.ProductCharacteristics..........................................................................................................................2
2.1ProductSpecifications......................................................................................................................2
2.2Features............................................................................................................................................2
2.3ProductFamily..................................................................................................................................2
2.4RelatedDocuments..........................................................................................................................3
3.UserInstruction......................................................................................................................................3
3.1Cleaning...........................................................................................................................................3
3.2CablePreparationandStrippingProcess........................................................................................4
3.3Crimpingofthecontacts..................................................................................................................5
3.4AssemblyProcess............................................................................................................................6
3.5ConnectorMatingandUn‐mating...................................................................................................8
3.6Dustcap............................................................................................................................................9
3.7CableRouting...................................................................................................................................9

INSTRUCTION MANUAL
Rev. A
Dongguan Zerun Electronics Technolog
y
Co.,Ltd.
( NO.1 Xianxi Industrial Park, Zhen‘an Road, Shangjiao, Chang’an Dongguan, Guangdon, P.R. China )
2 / 9
1. Scope
ThisManualcoverstherequirementsforapplicationoftheZ4S‐abcdeConnectoraswellasguideline
fortheassembly.
2. Product Characteristics
2.1ProductSpecifications
RatedSystemVoltage1500VDC(IEC/UL)
RatedImpulseVoltage16000V
RatedCurrent
35A(2.5mm2/14AWG)
40A(4.0mm2/12AWG)
45A(6.0mm2/10AWG)
ProtectionClassClassII
ProtectionDegree(mated/unmated)IP68(1m,1h)/IP2X
OperatingTemperature‐40℃~+85℃
2.2Features
zContactwithdrumtypecrownspring,makeelectricalconnectionfastness.
zRatchetmechanismtolockthenutcover,reliablyavoidbeingloosenedafterlongtermuse.
zSelf‐lockingbetweenthemaleandfemaleconnector,insertconvenientlyandreliably.
zStrongageingresistance,UVresistance,suitforusinginoutdoorsevereenvironment.
zCompatiblewithMC4typeconnectors(MC4,H4,PV4,etc.),TUV&ULcertificated.
zContactresistancelessthan0.30mΩ,lessheatingandlowpowerconsume.
2.3ProductFamily
Type Designation Z4S-abcde
a, b, c, d,e are variables
a: Type C: Cable mounting
P: Panel mounting
b: Releasing Method T: Tool is required
H: By hand
c: Rated Current 3: 35A (2.5mm2, 14AWG)
4: 40A (4.0mm2, 12AWG )
5: 45A (6.0mm2, 10AWG)
d: Cable Certificate
A: TUV 1000V
B: TUV 1500V
C: TUV&UL 1000V
D: TUV&UL 1500V
e: Housing Material 1: PA
2: PPE

INSTRUCTION MANUAL
Rev. A
Dongguan Zerun Electronics Technolog
y
Co.,Ltd.
( NO.1 Xianxi Industrial Park, Zhen‘an Road, Shangjiao, Chang’an Dongguan, Guangdon, P.R. China )
3 / 9









2.4RelatedDocuments
zCustomer Drawing Z4S_T001
zData Sheet Z4S_W005

3. User Instruction
3.1Cleaning
Any type of exposure to contaminants (dust, humidity etc.) can negatively affect the system with regards
to its functions, over the duration of use. This applies especially to the functionality of the connector
seals and crimped contact connections. Therefore, during assembly, it is necessary to ensure a careful
and clean processing environment.
Connector for cable mounting
Connector for panel mounting
Connector for un-mating by hand
Picture 1
Picture 2
Picture 3

INSTRUCTION MANUAL
Rev. A
Dongguan Zerun Electronics Technolog
y
Co.,Ltd.
( NO.1 Xianxi Industrial Park, Zhen‘an Road, Shangjiao, Chang’an Dongguan, Guangdon, P.R. China )
4 / 9
During storage, transportation and installation, it is necessary to protect the non-inserted contacts
against contamination from dust or moisture. Connectors should be protected with the appropriate
recommended dust caps* prior to being fully connected.
* Dust caps supplied by Zerun are available. Refer to section 3.6.
Articles which can erode the plastics must not be used to clean the products. We recommend the use of
soft cloths moistened with isopropyl alcohol for cleaning.
Un-mated contacts must be protected against moisture, dust and any environmental
pollution. Only clean and dry mated contacts fulfill their respective pollution class.
3.2CablePreparationandStrippingProcess
The possible connectable wire gauge sizes are 2.5 mm², 4.0 mm², 6.0 mm² (or AWG14, AWG12,
AWG10).
Use a strip tool* to strip cable 7.0±0.5mm* and be careful not to nick conductors. See Picture 4.
* Zerun specified strip tool can be used in this step.
* The strip length can refer to the mark on Zerun wrench. See Picture 5.
Adjust the striper stopper (Picture 6) and put the cable in corresponding notch to strip the length of 7mm.
7.0±0.5 Picture 4
Picture 5
Picture 6

INSTRUCTION MANUAL
Rev. A
Dongguan Zerun Electronics Technolog
y
Co.,Ltd.
( NO.1 Xianxi Industrial Park, Zhen‘an Road, Shangjiao, Chang’an Dongguan, Guangdon, P.R. China )
5 / 9
For the cable mounting type, If there is a visible deformation or damage appears at
the sealing area of the cable, which matches with the connector component in
following process, the cable end needs to be trimmed to remove the area.
3.3Crimpingofthecontacts
Zerun specified crimp tool should be used in this step.
Insert the contact into the corresponding crimping notch or locator (male or female) taking into account
the cable size used. Press the pliers gently together until the crimp s are properly located within the
crimping die. Insert the stripped cable end until the insulation comes up against the crimp insert.
Completely close the crimping pliers. See Picture 7.
See Picture 8 of crimp result.
When you insert striped cable into contact barrel, always insure all conductor
strands are captured in the contact barrel.
Picture 7
PRESS
Picture 8

INSTRUCTION MANUAL
Rev. A
Dongguan Zerun Electronics Technolog
y
Co.,Ltd.
( NO.1 Xianxi Industrial Park, Zhen‘an Road, Shangjiao, Chang’an Dongguan, Guangdon, P.R. China )
6 / 9
The cable pull-out forces requirement will have to be the following:
Cable size Cable pull –out force requirement
2.5 mm² (or 14AWG) Min. 230N (~50 Lbs)
4.0 mm² (or 12AWG) Min.320N (~70 Lbs)
6.0 mm² (or 10AWG) Min.360N (~80 Lbs)
3.4AssemblyProcess
Cable Monuting
Insert contact cable assembly into back of male and female connector. A “click” should be heard or felt
when the contact cable assembly is seated in correct position. Contacts cannot be removed once
seated. See Picture 9, 10, 11 and 12.
Back cap must be closed using a torque between 2.8 and 3.1Nm. Zerun wrench can be used in this
step. See Picture 13.
Picture 9 Picture 10
Picture 11 Picture 12
INSERT
INSERT
Picture 13
WRENCH

INSTRUCTION MANUAL
Rev. A
Dongguan Zerun Electronics Technolog
y
Co.,Ltd.
( NO.1 Xianxi Industrial Park, Zhen‘an Road, Shangjiao, Chang’an Dongguan, Guangdon, P.R. China )
7 / 9
Panel Mounting
Install on a flat, vertical housing surface which thickness of the housing wall not less than 1.5mm.
The diameter of the through-hole on the panel shall be between 12.9 mm and 13mm
The surface of the through-hole where match with o-ring shall be smooth, and there
shall be no burrs or other defects which might scrape the o-ring.
Insert the connector through the hole on panel, and then install the gasket and nut. See Picture 14.
During the process Zerun wrench can be used. See Picture 15.
Recommended torque of installing nut is 2 N.m.
Insert contact cable assembly into back of male and female connector. A “click” should be heard or felt
when the contact cable assembly is seated in correct position. Contacts cannot be removed once
seated. See picture 16.
Picture 14
INSERT
GASKET NUT
HOUSING WALL
Picture 15
WRENCH

INSTRUCTION MANUAL
Rev. A
Dongguan Zerun Electronics Technolog
y
Co.,Ltd.
( NO.1 Xianxi Industrial Park, Zhen‘an Road, Shangjiao, Chang’an Dongguan, Guangdon, P.R. China )
8 / 9
3.5ConnectorMatingandUn‐mating
For mating align the 2 half connectors and mate them together by hand until a “click” is heard and/or felt.
Pulling female and male connector to make sure the connector is firmly engaged. The force is 20N max.
For un-mating, Zerun wrench should be used in this step. Insert the flat blade and then pull out the
connector. See Picture 20.
Mating
Picture 17
Picture 18
Picture 19
Picture 20
FORCE
FLAT BLADE
FORCE
Picture 16
INSERT

Donggua
n
( NO.1 Xian
x
Attenti
o
3.6Du
Dust ca
p
3.7Ca
b
The cab
diamet
e
or conn
e
n
Zerun Electro
n
x
i Industrial Park,
Z
Do not
d
within t
h
injury o
r
o
n: The con
n
stcap
p
s serve for
t
b
leRouti
n
le must not
b
e
rmust be
m
e
ctions is pr
e
n
ics Technolog
y
Z
hen‘an Road, Sha
d
isconnect
th
h
e connecto
r
death. Ext
r
n
ector sho
u
t
he protectio
n
g
b
e bent or c
r
m
aintained.
T
e
vented.
INS
T
y
Co.,Ltd.
ngjiao, Chang’an
D
th
e connect
o
r ma
y
be el
e
r
eme cautio
n
u
ld onl
y
be
o
n against en
r
ushed on th
e
T
he cable m
P
T
RUCTIO
D
ongguan, Guangd
o
o
r while it i
s
e
ctricall
y
c
h
n
should b
e
o
pened b
y
a
vironmental
e
direct exiti
n
ust be route
d
Picture 22
P
icture 21
N MAN
U
o
n, P.R. China )
s
under an
e
h
ar
g
ed and
c
e
applied w
h
a
uthorized
a
contaminan
t
n
g. A minim
u
d
in a way t
h
R
U
AL
e
lectrical lo
a
c
apable of
i
h
en discon
n
a
nd trained
p
t
s. (Protecti
o
u
m bending
r
h
at tensile st
r
a
d. Compo
n
i
nflictin
g
se
n
ect the con
p
ersonne
l
.
o
n level IP44
r
adius R ≥
5
r
ess on the
c
Rev. A
9 / 9
n
ents
vere
nector.
).
5
x cable
c
onductor