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PowerWize Connectors

PowerWize High-Voltage, High-Current Wire-to-Board/Wire-to-Busbar Connectors are offered in two sizes, 6.00 and 8.00mm, suitable for applications requiring up to 1,000V and 190.0A. In addition, the headers can be mounted on either printed circuit boards or busbars.

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Product Highlights

 Current:  Contact Diameter: Operating Temperature:
up to 190.0A6.00 and 8.00mm-40 to +125°C

PCB Headers

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Connector Housings

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Crimp Terminals

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Connector Accessories

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Power and Signal Cable Assemblies

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Features and Benefits

Touch-safe individual silos: 
Protect and isolate each crimp contact to help ensure fingers cannot touch energized contacts.

Optimal current-carrying capacity:
Offers multiple contact beams to help ensure low contact resistance, low voltage drop and minimal heat generation at the contact interface.

Field installable with battery-powered applicators: 
Enables on-site cable assembly fabrication for applications where cable assembly lengths are uncertain until installation is underway.

Reliable crimp geometry with high-quality 8-sided crimp profile:
Helps ensure minimal contact resistance at the interface between the wire and the crimp barrel, contributing to the system’s minimal heat generation and higher current-carrying capacity compared to other designs.

Low mating and unmating forces: 
Enable operators to mate and unmate cable assemblies even in hard-to-reach or tight spaces

Non-conductive, touch-safe caps attached to header pins and individual silos: 
Protect and isolate each pin to help ensure fingers cannot touch energized pins

The TPA retainer slips over the stripped wire prior to crimping and after crimping it snaps into the receptacle housing: 
Offers a user-friendly cable assembly; helps ensure contact is fully engaged

Mechanically keyed and color coded with uniquely positioned ribs on header housings and matching slots on receptacles (based on connector color): 
Helps ensure only like-colored connectors mate; helps prevent mismating when multiple wire-to-board or wire-to-busbar interconnects are used in the same application

Crimp contacts are available in a wide range of wire gauges: 
Provides design and manufacturing flexibility.

Screw-mount headers attach securely to either busbars or printed circuit boards: 
Provides design and manufacturing flexibility.

Positive locking with active latches on receptacles and barbed geometry on headers: 
Provides operators tactile and audible feedback during system integration to help ensure secure mating; helps prevent cable assemblies from backing off headers due to shock, vibration, or mishandling.

Low Contact Resistance:
Sentrality Interconnects offer low contact resistance and low voltage drop so there is minimal heat generation at the contact interface, which results in higher current-carrying capacity compared to other contact designs.

Overview

Power efficiency is critical to cost management in large power-consuming operations such as data centers and telecom central offices. The COEUR socket incorporated into the PowerWize crimp contacts offers low contact resistance and low voltage drop at the contact interface due to its multiple contact beams.

Energized equipment, such as a server or a power supply array, needs to be safe to handle if a new device is being installed or a defective device is being removed and replaced. PowerWize headers and receptacles are designed to comply with industry-standard touch-safe requirements.

Identifying high-power wire-to-board or wire-to-busbar interconnects that can be attached to a wide range of substrates and crimped to a wide range of wire styles and wire gauges is challenging. PowerWize screw-mount headers can attach to either printed circuit boards or busbars. PowerWize crimp sockets can accept 1/0, 2, 4, 6, 8, or 10 AWG wires.

 

Applications by Industry

Battery Storage System
Gateway Storage System

Battery farms
Factory equipment
Robotics

Circuit breakers
Data storage units
Enterprise switches
Power distribution units (PDUs)
Routers
Servers
UPS/battery storage units

Data storage units
Digital cross-connect switches
Network routers
Power distribution units (PDUs)
Servers
Uninterruptable power supplies (UPSs)

This is not a definitive list of applications for this product. It represents some of the more common uses.

Frequently Asked Questions

How are the PowerWize headers, receptacles TPA retainers and crimp contacts packaged?
The headers and receptacle housings are tray packed. The TPA retainers and crimp contacts are bag packed.

Can Molex provide finished cable assemblies using PowerWize connectors?Yes. Molex’s cable assembly plants in China and India have the application tooling required to provide both early design cable assembly samples and production volume cable assemblies for this product family. Contact your local Molex sales engineer for support.

Can I crimp PowerWize contacts in the field and build custom-length cable assemblies on the job site?
Yes. Molex offers battery-powered hand tools and a wide range of die sets that allow customers to crimp our PowerWize connectors contacts in the field.

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