Molex Pico Blade Series 1.25mm Pitch Wire Harness Instruction Manual

1. Introduzzjoni

This manual provides comprehensive instructions for the Molex Pico Blade Series 1.25mm Pitch Wire Harness, model 51021-0200. These wire harnesses are designed for various applications including consumer electronics, automotive systems, medical devices, and industrial automation. Known for their compact size and 1.25mm pitch, they offer a cost-effective and reliable connection solution. This product supports both Wire-to-Wire (WTW) and Wire-to-Board (WTB) configurations.

2. Prodott Aktarview

The Molex Pico Blade Series wire harnesses are available in various configurations to suit diverse application needs. They are characterized by their small form factor and precise 1.25mm pitch, ensuring secure and efficient electrical connections.

2.1 Karatteristiċi ewlenin

• Disinn kompatt: Very compact connector with 1.25mm pitch.
• Versatili: Supports both Wire-to-Wire (WTW) and Wire-to-Board (WTB) configurations.
• Kosteffikaċi: Designed for efficient and economical use.
• Personalizzazzjoni: Options for various cable lengths, wire colors, and termination types.

2.2 Components and Materials

• Djar: Typically 51021-xx00 (Female) or 51047-xx00 (Male) series.
• Terminal: Female 50058-8000, Male 501258000.
• Hook Wire: UL1061 28AWG, rated 80°C, 300V. Some variants may use AFR250 0.12MM2 PTFE insulated silver plating copper wire (250V, 250°C).
• Kejbil taż-żigarella: UL1571 28AWG.
• Wire Color Options: Black, Red, Yellow, Blue, Orange, Green, White, Gray, Purple, Brown.
• Standard Cable Lengths: 50mm, 100mm, 150mm, 300mm, 450mm, 600mm.

2.3 Product Types

The wire harnesses come in several common types, each designed for specific connection requirements:

• TYPE BSE: Single End termination, typically with all black wires. Housing 51021-XX00. Conbeone P/N: CB030106.
• TYPE BDA: Dual Ends Type A termination, typically with all black wires. Housing 51021-XX00. Conbeone P/N: CB030101.
• TYPE BDB: Dual Ends Type B termination, typically with all black wires. Housing 51021-XX00. Conbeone P/N: CB030108.
• TYPE CSE: Single End termination, with colorful wires. Housing 51021-XX00. Conbeone P/N: CB030531.
• TYPE CDA: Dual Ends Type A termination, with colorful wires. Housing 51021-XX00. Conbeone P/N: CB030532.
• TYPE CDB: Dual Ends Type B termination, with colorful wires. Housing 51021-XX00. Conbeone P/N: CB030533.
• TYPE CSEP: Single End termination, with colorful wires and PVC tube covering. Housing 51021-XX00. Conbeone P/N: CB030534.
• TYPE CDAP: Dual Ends Type A termination, with colorful wires and PVC tube covering. Housing 51021-XX00. Conbeone P/N: CB030535.
• TYPE CDBP: Dual Ends Type B termination, with colorful wires and PVC tube covering. Housing 51021-XX00. Conbeone P/N: CB030536.

Figure 1: Various Wire Harness Product Types

3. Speċifikazzjonijiet

Figure 2: Receptacle and Ribbon Cable Assembly Specifications

Figure 3: Male (Plug) Assembly Specifications

Figure 4: Female (Receptacle) Assembly Specifications

4. Setup u Installazzjoni

Proper installation of the wire harness is crucial for optimal performance and safety. Always ensure power is disconnected from the system before making any connections.

4.1 Linji Gwida Ġenerali dwar il-Konnessjoni

1. Identify Connector Types: Determine if you are using a single-end, dual-end (Type A or B), male (plug), or female (receptacle) harness.
2. Pin Orientation: Pay close attention to the pin orientation (Pin 1, Pin N) as indicated in the diagrams. Incorrect orientation can lead to damage or malfunction.
3. Konnetturi tat-tgħammir: Ensure the wire harness connector is correctly aligned with its mating connector (e.g., on a PCB or another wire harness).
4. Konnessjoni Sikura: Gently but firmly push the connectors together until they are fully seated. Avoid excessive force.
5. Rotot tal-kejbil: Route cables to prevent strain, sharp bends, or contact with moving parts or heat sources.

4.2 Wiring Diagrams and Configurations

Refer to the following diagrams for specific wiring configurations and pinouts. The diagrams illustrate various termination types and how pins are connected.

Figure 5: General Wire Harness Configurations and Part Numbers

Figure 6: Termination Types (Single End, Dual Ends A/B, with/without PVC Tube)

For specific pin assignments and color coding, consult the detailed product specifications or contact technical support if you have a custom configuration.

5. Istruzzjonijiet Operattivi

Once installed, the wire harness operates passively as an electrical conduit. Ensure that the connected devices operate within the specified electrical parameters of the wire harness.

• Voltage u kurrenti: Taqbiżx il-vol massimutage rating of 300V. While specific current ratings are not provided in this manual, ensure that the current draw of connected devices is appropriate for 28AWG wire to prevent overheating.
• Kundizzjonijiet Ambjentali: Operate the wire harness within its specified temperature range (80°C for UL1061, 250°C for AFR250). Avoid exposure to harsh chemicals or extreme moisture unless the specific harness variant is designed for such conditions.
• Konnessjonijiet sikuri: Periodically check that all connections remain secure and free from vibration-induced loosening.

6. Manutenzjoni

Regular maintenance helps prolong the life and ensure the reliability of your wire harness.

• Spezzjoni Viżwali: Periodically inspect the wire harness for any signs of wear, fraying, cuts, or damage to the insulation or connectors.
• Indafa: Keep connectors clean and free from dust, dirt, and debris. Use a soft, dry brush or compressed air for cleaning. Avoid liquid cleaners unless specifically designed for electronics and applied sparingly.
• Ħażna: If the wire harness is not in use, store it in a dry, temperate environment, away from direct sunlight and corrosive substances. Avoid kinking or tightly coiling the cables.
• Ħsara: If any damage is observed, replace the wire harness immediately to prevent electrical hazards or system malfunction. Do not attempt to repair damaged wires or connectors unless you are a qualified professional with appropriate tools and materials.

7 Issolvi l-problemi

If you experience issues with your wire harness, consider the following troubleshooting steps:

• No Power/Signal:
  1. Verify that the wire harness is correctly connected at both ends.
  2. Check the pin orientation against the wiring diagrams (Figure 5, Figure 6) to ensure correct pinout.
  3. Inspect for any loose connections or dislodged pins within the connectors.
  4. Test continuity of the wires using a multimeter if possible.
• Konnessjoni intermittenti:
  1. Gently wiggle the connectors to see if the connection stabilizes. This may indicate a loose pin or a damaged wire.
  2. Inspect the wires near the connectors for any signs of internal breakage or stress.
  3. Ensure the mating connectors are clean and free from corrosion.
• Is-sħana żejda:
  1. Ensure the current flowing through the wires does not exceed the safe limits for 28AWG wire.
  2. Check for any short circuits or incorrect wiring that could cause excessive current draw.
  3. Ivverifika li t-temperatura ambjentali tkun fil-medda operattiva speċifikata.

Jekk il-problemi jippersistu wara li twettaq dawn il-verifiki, ikkuntattja l-appoġġ tekniku għal aktar assistenza.

8. Għajnuniet għall-Utenti

Ma kien hemm l-ebda pariri speċifiċi għall-utent disponibbli minn reviews or Q&A for this product. However, general best practices for wire harnesses include:

• Always double-check pin assignments before making final connections, especially for custom setups.
• Use appropriate strain relief where cables enter or exit enclosures to prevent damage over time.
• Consider using heat shrink tubing or cable ties to manage and protect wiring bundles.

9. Garanzija u Appoġġ

For technical support, customization inquiries, or any questions regarding your Molex Pico Blade Series wire harness, please contact the manufacturer:

• Persuna ta' Kuntatt: Roy Wang
• Email: roy.wang@conbeone.com
• Skype: roy.wang@conbeone.com

CAD drawings may be available on the manufacturer's websit.