TE CONNECTIVITY 1643906-1

BUSBAR CONNECTIVITY QUICK REFERENCE GUIDE THINGS TO CONSIDER WHEN CHOOSING BUSBAR PRODUCTS Application: Properties like dimensions, shape, isolation, plating, base material, and use of connector should be considered when choosing a busbar product. Current and Voltage: Does the connector require power only, or a combination of power and signal? How much current is required in the application? Keep in mind that busbar products performance is usually measured in amperes (or amps). The voltage is also highly important as it defines the spacing between the contacts and is related to safety requirements. Hot-Pluggability: Will the application be mated while under electrical load? If so, a hot- pluggable connector is required. Many of the products in this guide have been approved for use in hot-plug applications. TYPICAL POWER CONNECTOR APPLICATIONS • Busbar based power distribution • Servers, storage & network routers • Power racks • Industrial • Rack mounted switching power supplies • Computer • Core network energy systems • Modular power supply • Cellular base stations • Alternative (green) energy systems) • PSU power distribution • Power inverters DATA AND DEVICES /// BUSBAR CONNECTIVITY CROWN CLIP Connectors CROWN CLIP Jr. Connectors Screw Mount Solder Tail Reference Part Number* Reference Part Numbers* 1982995-1 | 1982995-2 2178410-1 | 2178411-1 | 1551953-1 • Mates directly to a power bus bar • Blind mate • Provides a space efficient interconnection in solder or • Hot pluggable screw mount configurations • Copper busbar, plated nickel or suitable alternative • Low insertion/extraction forces • Current = 170A • Ideal for power supply/distribution applications • Anti Over Stress Feature • Bus Bar misalignment: ± .75 mm • Mating Bus Bar Thickness: 3.0 ± 0.1 mm CROWN CLIP Sr. Connectors CROWN CLIP Sockets CROWN CLIP II Sockets Dual CROWN CLIP Sockets Reference Part Number* Reference Part Number* Reference Part Number* 1643906-1 1643903-1 1926671-1 CROWN CLIP Sockets Features: • Compact, high-current, blind-mate design. Supports true hot-plug, complying with safety regulatory requirements for current interruption under load. • Utilizes the well-known ELCON CROWN BAND contact technology. • Mates to a solid blade (CROWN CLIP) or laminated bus bar tabs for feed and return currents (CROWN CLIP II and Dual CROWN CLIP). • CROWN CLIP is a single pole, float mount socket provides up to 6 degrees of float. CROWN CLIP II is a dual pole, float- mount socket offering +/- 1.0mm of bus bar misalignment. Dual CROWN CLIP is a dual pole, feed-through socket allowing insertion of mating blade from both top or bottom of socket. • Mating bus bar blades to be .125” (3.18mm) or .118” (3.00mm) thick. Insertion length .650” (16.50mm) minimum, 1.00” (25.40mm) maximum Rated Current Part Number Length (mm [in1]) Width (mm [in1]) Comment Current Interruption 36.45 25.40 100A at 48V CROWN CLIP 1643906-1 Single Pole 300A [1.435] [1.000] 200A at 42V 36.45 25.40 100A at 48V CROWN CLIP II 1643903-1 Dual Pole 300A [1.435] [1.000] 200A at 42V 35.56 25.40 100A at 60V Dual CROWN CLIP 1926671-1 Dual Pole 350A [1.400] [1.000] 200A at 5V 1982995-1 1982995-2 35.56 26.67 2178410-1 CROWN CLIP Jr. Feed Through 170A - 2178411-1 [1.400] [1050] 2178531-1 1551953-1 *Part numbers listed are examples of some available samples, please visit website for additional and mating part numbers DATA AND DEVICES /// BUSBAR CONNECTIVITY PAGE 2 Pluggable Busbar Connectors Features • Board-to-Busbar, Wire-to-Busbar, Board-to-Busbar • Silver plated Copper alloy • Mate with .125” or .062” thick plated bus bar providing a separable connection that eases assembly, inspection, and troubleshooting • Ideal for computer, industrial control, modular power supply or other applications that demand low millivolt drop and reliable separation. Commonly used in rack-mounted equipment with bus bar architecture. • Blind mateable (misalignment up to + .060” [1.52mm] for both series) 125 Series Reference Part Number* Reference Part Number* Reference Part Number* 104502-1 104501-1 213647-1 Dimensions Series Part Number • Contact Rated Current = 500 A “A” (Width) “B” (Height) “C” (Length) • 100 mating cycles minimum 2.290 1.141 3.200 104502-1* • 1” [25.4mm] minimum width 58.17 28.99 81.28 bus bar .850 1.122 3.294 104501-1* 125 Series Fits 21.59 28.5 83.67 Busbar .125 1.250 1.141 1.993 [3.18] Thick 213647-1 31.75 28.99 50.61 1.25 1.01 2.00 2212011-1 31.8 25.8 50.9 *Busbar or Cable Power Feed 062 Series Reference Part Number* Reference Part Number* 104729-1 104742-2 Dimensions Series Part Number “A” (Width) “B” (Height) “C” (Length) • Contact Rated Current = 250 A • 50 cycle minimum 1.360 .705 1.342 104729-1 062 Series Fits 34.54 17.91 34.09 • ½” [12.7mm] minimum width Busbar .062 busbar .356 .705 1.342 [1.57] Thick 104742-2 9.04 17.91 34.09 *Part numbers listed are examples of some available samples, please visit website for additional and mating part numbers DATA AND DEVICES /// BUSBAR CONNECTIVITY PAGE 3 RAPID LOCK Quick Connect/Disconnect Busbar Connectors Features 2 - #2 wire 4 - #4 wire 8 - #12 wire • Replacement for threaded studs Temperature Rise 50 • No loose nuts = no fretting/heat rise 45 • Quick Connect/Disconnect 40 • Safety Locking feature 35 • Currents from 50A to 250A 30 2 25 • Wire sizes from 2.5 to 95mm 20 • Color coding available 15 • Straight and right angle versions 10 5 0 Pin Contacts - Swage Type CURRENT, AMPERES Current Type Type Size Part No Rating Socket Connectors - Right Angle Pin Contact Swage #8 50A 6648221-1 Current Pin Contact Swage #4 120A 6648222-1 Part No Size Wire Size Color* Rating Pin Contact Swage #2 150A 6648223-1 6648237-1 #8 AWG #12 Black Pin Contact Swage 12mm 250A 1857523-3 6648228-1 #8 AWG #8 50A Black 1766484-1 #8 AWG #6 Black Pin Sockets - Screw and Washer Type 6648235-1 #4 AWG #8 Black 6648239-1 #4 AWG #6 110A Black Current Type Type Part No Size Rating 6648236-1 #4 AWG #4 Black Pin Screw & 2085957-1 #4 120A 6648238-1 #2 AWG #2 150A Black Contact Washer 6648234-1 #2 AWG #0 Black Pin Screw & 6648226-1 #2 150A 2 Contact Washer 1857547-1 12mm 95mm 250A Red *Black, Red and Blue colors available Insulation Boots Socket Connectors - Straight Wire Current Part No Size Color Type Size Color Part No Size Rating 1651003-1 #4 #8 Black Plastic locking hood #8 Black 1643279-1 1651003-2 #4 #8 Red Plastic locking hood #8 Red 1643279-2 1651003-3 #4 #8 Grey Plastic locking hood #8 Blue 1643279-3 1651003-4 #4 #8 Blue Socket contact #8 #8 50A 6648317-1 1766600-1 #2 Black Plastic locking hood #4 Black 1651766-1 1766600-2 #2 Red Socket contact #4 #4 120A 6648434-1 1766600-3 #2 Grey 1766600-4 #2 Blue Part numbers listed are examples of some available samples, please visit website for additional and mating part numbers DATA AND DEVICES /// BUSBAR CONNECTIVITY PAGE 4 AMPOWER Wave Crimp System Features • Insulated flat copper cable conductors and associated • Variety of interfaces for end of cable or mid-cable interface components enable solutions to power distribution terminations enable high application versatility and challenges through its unmatched packaging flexibility. customization. • Single and dual conductor cable types with various conductor • Flat cables can be easily formed and will hold their and insulation thicknesses available. Standard cable types shape, enabling high packaging flexibility. Cables can be support 80-135 Amps and operating voltages up to 600V. easily routed through confined spaces. • Flat power cables offer a number of advantages over both • Fully touch-safe. Less copper compared to round round jacketed power cables or traditional bus bars. jacketed cable; therefore less weight and lower cost per ampere of rated current. Copper Cable Options Max Part Width Thickness Copper Conductor(s) Operating Color Current Number (mm [in1]) (mm [in1]) W (inch[mm]) x T (inch [mm]) Voltage (A) 1-765210-7 1.018 (25.86) 0.024 (0.61) 1 x 0.987 (25.07) x 0.01 (0.25) Blue 300 80 1-765210-8 1.018 (25.86) 0.034 (0.86) 1 x 0.987 (25.07) x 0.02 (0.51) Blue 300 110 1-765210-9 1.018 (25.86) 0.024 (0.61) 2 x 0.45 (11.43) x 0.01 (0.25) Blue 300 40/40 2-765210-0 1.018 (25.86) 0.034 (0.86) 2 x 0.45 (11.43) x 0.02 (0.51) Blue 300 55/55 2-765210-3 0.484 (12.29) 0.024 (0.61) 1 x 0.45 (11.43) x 0.01 (0.25) Blue 300 40 2-765210-4 0.484 (12.29) 0.034 (0.86) 1 x 0.45 (11.43) x 0.02 (0.51) Blue 300 55 2-765210-5 1.018 (25.86) 0.044 (1.12) 1 x 0.987 (25.07) x 0.03 (0.76) Red 300 135 2-765210-6 1.018 (25.86) 0.052 (1.32) 1 x 0.987 (25.07) x 0.03 (0.76) Red 600 135 2-765210-7 1.018 (25.86) 0.052 (1.32) 1 x 0.987 (25.07) x 0.03 (0.76) Blue 600 135 2-765210-8 0.484 (12.29) 0.034 (0.86) 1 x 0.45 (11.43) x 0.02 (0.51) Red 300 55 2-765210-9 1.018 (25.86) 0.034 (0.86) 2 x 0.45 (11.43) x 0.02 (0.51) Red 300 55/55 3-765210-0 1.018 (25.86) 0.034 (0.86) 1 x 0.987 (25.07) x 0.02 (0.51) Red 300 110 Circular Approx MILS AWG Amps Per Conductor 12,566 9 80 5,729 13 40/40 25,133 6 110 11,459 10 55/55 DATA AND DEVICES /// BUSBAR CONNECTIVITY PAGE 5 AMPOWER Wave Crimp System Cable-to-Cable Connectors Tail Tail Part Number Description Length Type (inch) 765191-1 slim plug N/A N/A Cable Receptacle Mid-Cable Termination 765478-1 slim recepticle N/A N/A .250 FASTON Tab Tap Cable to Cable 766569-1 N/A N/A Recepticle PM* 766569-1 PM needs: 765530-1, 765245-1 N/A N/A Cable to Cable 766569-1 N/A N/A Recepticle STR** 766569-1 STR needs: 765529-1, 765245-1 N/A N/A PCB-Mounted Header *PM = Panel Mount **STR = Sqeeze-to-Release Blindmate PCB-Mounted Headers PCB Mounted Headers Tail Tail Length Tail Tail Part Number Description Type (inch) Part Number Description Length Type (inch) 5765527-1 2 Cable Vert Header Solder 0.131 1-765206-7 slim vert header Solder 0.131 5765527-2 2 Cable Vert Header Solder 0.165 1-765206-8 slim vert header Solder 0.165 765608-1 2 Cable R/A Header Solder 0.273 1-765206-9 slim vert header Solder 0.225 5765208-1 4 Cable Vert header Solder 0.131 2-765206-0 slim vert header with eyelet Solder 0.131 5765208-2 4 Cable Vert header Solder 0.165 765271-1 slim vert header Press Fit 0.144 5765208-3 4 Cable Vert header Solder 0.235 765204-5 slim R/A header Solder 0.124 5765208-4 4 Cable Vert header Solder 0.305 765204-6 slim R/A header Solder 0.165 766510-1 4 Cable R/A Header Solder 0.273 765208-5 4 Cable Vert header Press Fit 0.144 Mid-Cable Terminations Blindmate Cable-Mounted Receptacles Tail Tail Tail Tail Part Number Description Length Part Number Description Length Type Type (inch) (inch) 765528-1 2 Cable housing N/A N/A 765277-1 Tap N/A N/A 765529-1, 765209-1, 765311-1 Side Tap, R/A N/A N/A 765528-1 needs: N/A N/A 768209-2 765275-1 Side Tap, Jogged N/A N/A 765247-1 4 Cable housing N/A N/A 765276-1 .250 FASTON Tab Tap N/A N/A 765248-1, 765209-1, 765247-1 needs: N/A N/A 768209-2 Terminal Block Interface Stud Interface Part Centerline Hole Size Stud Size Hole Size Description Part Number Description Number [inch,(mm)] [inch,(mm)] [inch,(mm)]) [inch,(mm)] 765228-1 Full-Width Cover 765228-1 Cover Termination 0.171 x 0.250 765216-1 0.562 (14.27) Termination Assembly, .562 (4.34 x 6.35) 765226-1 Assembly for 0.250 (6.35) 0.266 (6.76) 1/4 Termination 0.270 x 0.296 765225-1 0.688 (17.48) Assembly, .688 (6.86 x 7.52) Termination 765226-2 Assembly for 0.312 (7.92) 0.328 (8.33) 765229-1 Half-Width Cover 5/16 Termination 0.171 x 0.250 765216-1 0.562 (14.27) Assembly, .562 (4.34 x 6.35) Termination 0.270 x 0.296 765225-1 0.688 (17.48) Assembly, .688 (6.86 x 7.52) DATA AND DEVICES /// BUSBAR CONNECTIVITY PAGE 6 Associated Content Open Compute Project (OCP) Bus Bar Clip and Cable Assemblies QRG (Doc # 1-1773867-8) 2-Piece Power Connectors QRG (Doc # 4-17773458-1) TE also has a broad offering of cable-mounted bus bar connectivity solutions; contact TE for more details. For More Information TE Technical Support Center USA: 1.800.522.6752 Canada: 1.905.475.6222 Mexico: 52.0.55.1106.0800 Latin/S. America: 54.0.11.4733.2200 Germany: 49.0.6251.133.1999 UK: 44.0.800.267666 France: 33.0.1.3420.8686 Netherlands: 31.0.73.6246.999 China: 86.0.400.820.6015 te.com/products/busbar © 2017 TE Connectivity Ltd. family of companies. All Rights Reserved. AMP, AMPOWER, CROWN CLIP, ELCON, RAPID LOCK, TE Connectivity, TE, TE Connectivity (logo) and Every Connection Counts are trademarks of the TE Connectivity Ltd. family of companies. Other logos, product and company names mentioned herein may be trademarks of their respective owners. 1-1773701-9 DND 04/2017 While TE has made every reasonable effort to ensure the accuracy of the information in this brochure, TE does not guarantee that it is error-free, nor does TE make any other representation, warranty or guarantee that the information is accurate, correct, reliable or current reserves the right to make any adjust- ments to the information contained herein at any time without notice. TE expressly disclaims all implied warranties regarding the information contained here- in, including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose. The dimensions in this catalog are for reference purposes only and are subject to change without notice. Specifications are subject to change without notice. Consult TE for the latest dimensions and design specifications. DATA AND DEVICES /// BUSBAR CONNECTIVITY