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Home [Special Page] ZH05 Series

Highly Reliable Connector that Prevents Electric Shock to Workers, Short Circuit due to Dust Adhesion and Meets Automotive Quality Standards

ZH05 Series Wire-to-Board Connector for Electric Shock Prevention

Ideal for Battery Electric Vehicles (BEV) and Hybrid Electric Vehicles (HEV/PHEV).

ZH05 Series Wire-to-Board Connector for Electric Shock Prevention

Against the backdrop of stricter environmental regulations around the world, HEV, PHEV, BEV, FCV and other vehicles that use electric motors, known as “New Energy Vehicles,” are spreading at a faster pace. Along with this trend, the role of automotive electrical components including connectors has become more important than ever as vehicle electrification advances.

The automotive connector ZH05 Series is designed to withstand temperatures of up to 125°C and has high vibration resistance. In addition, it is designed to prevent short circuits caused by dust adhesion and electric shocks to workers. This automotive connector can be used for a wide range of automotive electronic components such as automotive batteries, automotive chargers, and various ECUs.

Usage in Automotive Battery

Usage in Automotive Battery
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Specifications

Rated Current  2A
Rated Voltage  60V AC
Operating Temperature  -40 to + 125°C
(Includes the temperature rise by current flow.)
Contact Resistance  10mΩ Max. (1A DC)
Insulation Resistance  100MΩ Min. (500V DC)
Withstanding Voltage  1,000V AC for 1 min.
Mating Durability  30 times

Applicable Cable

0.2-0.35SQ, Outer diameter 1.4mm Max. (FLRY)

No. of Pos.

Mass Production: 16pos.
Under Development: 12, 20pos.
Under Planning: 24pos.

Features

A Female contact is used for the board-side connector, and the contact is surrounded by resin to prevent short circuit and electric shock.

A wire-to-board connector with rod-shaped, protruding male contacts on the board-side is typically used to connect the live parts that monitor the on-board battery voltage, etc. However, in the case of conventional connectors, there is a short circuit hazard due to dust sticking between adjacent contacts and a risk of electric shock when an worker touches a contact during insertion and removal work.
The ZH05 uses a box-shaped female contact for the board-side connector. By physically surrounding the contact with resin to insulate, Hirose has achieved an innovative electric shock prevention design.

A Female contact is used for the board-side connector, and the contact is surrounded by resin to prevent short circuit and electric shock.

22.9mm Narrow Width for 050 Tab Size Contributes to Space Reduction (For 16pos.)

In order to increase battery module capacity the connector is often installed on the side of the module. In such designs the mating surface of the connector must be turned sideways to prevent water intrusion from the top surface due to condensation. However, this results in problems with strength because the module case has to be reduced to accommodate the width of the connector. The ZH05 has a width of 22.9mm (16pos.), which is the amongst the smallest for 050 tab sizes, and helps to improve battery reliability and capacity by minimizing the impact on the case.

22.9mm Narrow Width for 050 Tab Size Contributes to Space Reduction (For 16pos.)
Header:ZH05-16DS-2H(A)、Plug:ZH05-16DP-HU(A)
No. of Pos. 12 16 20
Dimension A (mm) 18.9 22.9 26.9

Potting

Hirose’s original, patent-pending design is potting (resin encapsulation) compatible. Potting processing makes ZH05 safe to use even in an environment where condensation easily forms.

Withstands Continuous Vibration During Engine Operation and Driving

The female contact has a double-layered spring design for higher contact force than a single spring and suppresses the influence of vibration from the outside. In addition, three contact points are provided for each line on the top and bottom to maintain stable contact even under continuous vibration.

Increase the contact force and prevents vibration from outside.

Increase the contact force and prevents vibration from outside.

Withstands severe vibration due to improved contact reliability.

Withstands severe vibration due to improved contact reliability.

Comparison with Internal Connection Connector for Automotive Battery ZE05 Series

The ZE05 Series is slightly wider than the ZH05 Series, but is lower profile and shorter in depth, so you can choose the connector that best suits your needs.

Series Name ZH05 ZE05
Dimensions
(Example: 16pos.)
ZH05 Narrow Width ZE05 Low Profile & Short Depth
Contact 0.5 size, Tin Plated 0.5 size, Tin Plated
Contact Pitch 2.0mm 2.0mm
Rated Current 5A (Mono-Pole Power Supply),
2A (All-Pole Power Supply)
5A (Mono-Pole Power Supply),
2A (All-Pole Power Supply)
No. of Pos. (Currently in Mass Production) 16pos. (Single-row) 2, 4 (Single-row)
5, 8, 12, 16, 20, 24 (Double-row)
Electric Shock Prevention  ✔  -
Resin Sealing  ✔  ✔
Click here for ZE05 feature page

Applications (Use Case)

Automotive electrical equipment such as batteries, onboard chargers, and various ECUs.
Industrial Storage Batteries, Storage Battery Modules, Fuel Cells, etc.
Inquiry
Series Page