HRS ZE064-2022PCF, Handling Manual

Page 1: ...E ZE064W SERIES HANDLING MANUAL APPROVED HK UMEHARA 20220209 CHECKED HH TSUKUMO 20220209 DESIGNED TY MOGI 20220209 WRITTEN TY MOGI 20220209 TECHICAL SPECIFICATION ETAD T0947 00 0 1 32 FORM HC0011 9 1 HIROSE ELECTRIC CO LTD Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 2: ...IONS 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 CRI...

Page 3: ...tion 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 Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO ...

Page 4: ... 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 Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 5: ... 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 Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 6: ...nnector 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 Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights...

Page 7: ... 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 F...

Page 8: ...ention 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 ins...

Page 9: ... 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 sha...

Page 10: ...32 FORM HC0011 9 2 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 Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 11: ...MINALS 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 Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 12: ...rminal 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 Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 13: ...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 Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 14: ...irection 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 Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 15: ...fter 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 Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 16: ... 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 Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 17: ...r 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 Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 18: ...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 Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 19: ...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 Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 20: ...hat 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 Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 21: ...n insufficient slippage when installed on the panel causing it to not install properly and compromising air tightness 2 With the orientation of the polarity protrusions on the housing aligned with the indentations on the enclosure insert the harness end side through the enclosure opening until the male connector panel seal touches the enclosure opening Housing Black or grey Cable Terminal Inside t...

Page 22: ...ctor diagonally or pulling the harness side into the enclosure opening may cause excessive load on the male connector which may result in damage 4 Remove your hand from the male connector Insert M5 size screws through the two collars and tighten the screws to a tightening torque of 5 5Nm max to secure the unit to the panel Chamfer of the panel frontage Chamfer of the panel frontage Flange Panel se...

Page 23: ...te amount of lift 2mm or less or no panel seal is visible through the gap Do not reattach the male connector to the panel more than once and only do so consecutively to the same panel Before reattaching the harness check the appearance of the panel seal and if it is damaged or deformed use a new harness Also reattaching the male connector more than once or reattaching it to a different panel may c...

Page 24: ...ction of the male and female connectors and insert them straight along the mating direction 2 Please insert the connectors until they butt against each other The connector will be locked Do not touch the female connector lock lever when inserting the connector This makes it difficult to recognize the lock feeling and may cause half insertion Lock convexity Male connector Female connector Lock leve...

Page 25: ... locking lever of the female connector is pushed against it then grasp the female connector housing and pull it straight against the mating direction If the female connector is removed while the lock lever is not pushed down enough it may cause damage to the lock lever Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 26: ... your fingers to return to the pre set state Pre set Set Note Please return to the pre set state position from retainer wide side when the retainer drops out Retainer narrow side Make sure that the retainer is in the pre set state for both left and right Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 27: ...to the next section 9 for details on the repair tool Supplemental figure for repair tool direction Note Please be careful not to touch the terminal when inserting a repair tool Note Repaired connector cannot be used Please replace it with new one 1 Push 2 Pull Repair tool Repair tool insertion hole Terminal Terminal Repair tool Repair tool insertion hole Feb 1 2022 Copyright 2022 HIROSE ELECTRIC C...

Page 28: ...he tool on the retainer to housing lock lever side and push in the direction indicated by the arrow Note Please return to the pre set state position when the retainer drops out Dedicated tool Dedicated tool Retainer When the tool is pushed into the retainer returns to the pre set state Make sure that the retainer is in the pre set state for both left and right Feb 1 2022 Copyright 2022 HIROSE ELEC...

Page 29: ...ole and push until it hits After pushing in please remove the terminal while maintaining that state Note Insertion into the same terminal hole is limited to 2 times Please use the new housing after the third time Dedicated tool 1 Push 2 Pull Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 30: ...r summary for retainer repair tools Applicable parts Repair tool name Repair tool part number ZE064W XDS HU R Y ZE064W DS HU R CV MD 902 5151 0 The following drawing shows definition of tool for retainer release for female connector Under preparation Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 31: ...l repair tool Applicable part Repair tool name Repair tool part number ZE064 2022PCF ZE064 P RE MD 902 5150 0 ZE064 2022SCF ZE064 S RE MD 902 5149 0 The following drawings show definition of tools for terminal repair Terminal repair tool for ZE064 2022PCF Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 32: ...HIROSE ELECTRIC CO LTD ETAD T0947 00 0 32 32 FORM HC0011 9 2 Terminal repair tool for ZE064 2022SCF Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 33: ...following areas examples with ZE064W 24DP HU R A and ZE064W 24DS HU R A Male connector example with ZE064W 24DP HU R A Note Please pay attention to not touch panel seal Female connector example with ZE064W 24DS HU R A Areas to clamp the male connector Areas to clamp the female connector around cavities Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 34: ... 34 32 FORM HC0011 9 2 12 2 LOCATION OF TEST PROBES The test probes should be located in front face as described below Example with the 24P Male connector Female connector Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 35: ...PROBES The recommended probe should have the following characteristics Diameter 0 60mm maximum Plating Gold plated Spring force 1N maximum Stroke see section below Male connector Female connector 0 6mm max Gold plated Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 36: ...ELECTRICAL TESTS Perform test after insertion of terminals and closing of retainer Avoid any deformation on housing or terminal during electrical test Replace any damaged housing or terminal or panel seal with a new one Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 37: ...022PCF and ZE064 2022SCF 13 2 APPLICABLE WIRE Applicable wire size 0 3mm 0 5mm Applicable insulation size 1 4mm 1 7mm 13 3 QUALITY STANDARD Related dimensions for ZE064 2022PCF N N wire barrel cross section image O O insulation barrel cross section image P enlarged view Cover remaining N N O O P Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 38: ...32 FORM HC0011 9 2 Related dimensions for ZE064 2022SCF N N wire barrel cross section image O O insulation barrel cross section image N N O O P P enlarged view Cover remaining Feb 1 2022 Copyright 2022 HIROSE ELECTRIC CO LTD All Rights Reserved ...

Page 39: ...3 Width Wire barrel I 1 5 max Insulation barrel J 1 8 max Height of metal cut out teeth K 0 12 max Cut off tab L 0 1 max Note 1 Refer to a Crimping condition list for the crimp height Note 2 There is a possibility that a terminal is involved in covering and crowded by the crimping but it s no problem on the product function Note 3 Please confirm that the terminal which did crimp enters a housing F...

Page 40: ...821 22 0 83 0 89 1 5 max 1 90 2 00 1 8 max 50N AESSX0 5f 0 5387 20 0 90 0 96 1 5 max 2 00 2 10 1 8 max 70N Crimp parameters for terminal ZE064 2022SCF WIRE TYPE SEC AREA mm AWG CONDUCTOR INSULATION Tensile strength of the wire terminal link minimum C H C W C H C W AESSX0 3f 0 3821 22 0 84 0 90 1 5 max 1 90 2 00 1 8 max 50N AESSX0 5f 0 5387 20 0 92 0 98 1 5 max 2 00 2 10 1 8 max 70N Feb 1 2022 Copy...