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BUSBAR CONNECTIVITY QUICK REFERENCE GUIDE THINGS TO CONSIDER WHEN CHOOSING BUSBAR PRODUCTS Application: Properties like dimensions, shape, isolation, plating, base material, and use of connectors 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 Power racks Rack mounted switching power supplies Core network energy systems Cellular base stations PSU power distribution DATA AND DEVICES /// BUSBAR CONNECTIVITY • • • • • • Servers, storage & network routers Industrial Computer Modular power supply Alternative (green) energy systems Power inverters CROWN CLIP Connectors CROWN CLIP Jr. Connectors Screw Mount Solder Tail Reference Part Numbers* 1982995-1 | 1982995-2 Reference Part Numbers* 2178410-1 | 2178411-1 | 1551953-1 • Mates directly to a power busbar • Provides a space efficient interconnection in solder or screw mount configurations • Low insertion/extraction forces • Ideal for power supply/distribution applications • Busbar misalignment: ± .75mm • • • • • • Blind mate Hot pluggable Copper busbar, plated nickel or suitable alternative Current = 170A Anti-overstress feature Mating busbar thickness: 3.0 ± 0.1mm CROWN CLIP Senior Connectors CROWN CLIP Sockets Reference Part Number* 1643906-1 CROWN CLIP II Sockets Reference Part Number* 1643903-1 Dual CROWN CLIP Sockets Reference Part Number* 1926671-1 CROWN CLIP Sockets Features: • Compact, high-current, blind-mate design. Supports true hot-plug, complies with safety regulatory requirements for current interruption under load. • Utilizes the well-known ELCON CROWN BAND contact technology. • CROWN CLIP connector could mate with the solid busbar blade (CROWN CLIP Std) or laminated busbar blade (CROWN CLIP II and Dual CROWN CLIP). • CROWN CLIP Std is a single pole, and floating mount socket. CROWN CLIP II is a dual pole, floating mount socket, offering ±1.0mm floating contact and ±6° misalignment capability. Dual CROWN CLIP is a dual-pole, feed-through socket, allowing insertion of mating blade from both top or bottom of socket. • Mating busbar blades to be .125” (3.18mm) or .118” (3.00mm) thick. Insertion length .650” (16.50mm) minimum, 1.00” (25.40mm) maximum. Part Number Length (mm [in1]) Width (mm [in1]) Comment Rated Current Current Interruption CROWN CLIP 1643906-1 36.45 [1.435] 25.40 [1.000] Single Pole 300A 100A at 48V 200A at 42V CROWN CLIP II 1643903-1 36.45 [1.435] 25.40 [1.000] Dual Pole 300A 100A at 48V 200A at 42V 1926671-1 _______ 35.56 [1.400] __________ 25.40 [1.000] ___________ 30 [1.18] 20.6 [0.81] 35.56 [1.400] 26.67 [1050] Dual CROWN CLIP 2204899-1 CROWN CLIP Jr. 1982995-1 1982995-2 2178410-1 2178411-1 2178531-1 1551953-1 Single OR Dual Pole Feed Through 350A 100A at 60V 200A at 5V 170A - *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 • Silver plated Copper alloy • Mate with .125” or .062” thick plated busbar 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 busbar architecture. • Blind mateable (misalignment up to + .060” [1.52mm] for both series) Busbar Connector Overview 50A Connector 2204288-1 200A Connector 2204080-1 300A Connector 2204761-1 500A Connector 2204273-2 Dual Pole 500A Connector 2204866-1 Part Number Power Rating Busbar Mating Width Application 2204761-1 12V or 48V, 300A 3mm Power Shelf, BBU Shelf, Cubby Shelf 2204288-1 12V or 48V, 50A 3.56mm Power Shelf, BBU Shelf, IT Tray 2204600-1 12V or 48V, 125A 3mm Power Shelf, BBU Shelf, IT Tray 2204273-1 12V or 48V, 500A 3mm Power Shelf, BBU Shelf, Cubby Shelf 2204080-1 12V or 48V, 200A 3mm Power Shelf, BBU Shelf, IT Tray 2204866-1 12V or 48V, 500A 6mm BBU Shelf, IT Tray 2204761-1 12V or 48V, 300A 3mm Power Shelf, BBU Shelf, IT Tray DATA AND DEVICES /// BUSBAR CONNECTIVITY PAGE 3 Pluggable Busbar Connectors 125 Series Reference Part Number* 104502-1 Reference Part Number* 104501-1 Series • Contact Rated Current = 500A Part Number 125 Series Fits Busbar .125 [3.18] Thick Dimensions “A” (Width) “B” (Height) “C” (Length) 104502-1* 2.290 58.17 1.141 28.99 3.200 81.28 104501-1* .850 21.59 1.122 28.5 3.294 83.67 213647-1 1.250 31.75 1.141 28.99 1.993 50.61 2212011-1 1.25 31.8 1.01 25.8 2.00 50.9 • 100 mating cycles minimum • 1” [25.4mm] minimum width busbar Reference Part Number* 213647-1 *Busbar or Cable Power Feed 062 Series Reference Part Number* 104742-2 Reference Part Number* 104729-1 Series 062 Series Fits Busbar .062 [1.57] Thick Part Number Dimensions “A” (Width) “B” (Height) “C” (Length) 104729-1 1.360 34.54 .705 17.91 1.342 34.09 104742-2 .356 9.04 .705 17.91 1.342 34.09 • Contact Rated Current = 250A • 50 cycle minimum • ½” [12.7mm] minimum width busbar *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 RAPID LOCK Quick Connect/Disconnect Busbar Connectors Features 2 - #2 wire • Replacement for threaded studs 50 • No loose nuts = no fretting/heat rise 45 • Quick Connect/Disconnect 40 • Safety Locking feature 35 • Currents from 50A to 250A 30 • Wire sizes from 2.5 to 95mm2 25 • Color coding available 20 • Straight and right angle versions 4 - #4 wire 8 - #12 wire Temperature Rise 15 10 5 0 Pin Contacts - Swage Type CURRENT, AMPERES Type Type Size Current Rating Part No Pin Contact Swage #8 50A 6648221-1 Pin Contact Swage #4 120A 6648222-1 Pin Contact Swage #2 150A 6648223-1 Pin Contact Swage 12mm 250A 1857523-3 Socket Connectors - Right Angle Pin Sockets - Screw and Washer Type Type Type Part No Size Current Rating Pin Contact Screw & Washer 2085957-1 #4 120A Pin Contact Screw & Washer 6648226-1 #2 150A Part No Size Wire Size 6648237-1 #8 AWG #12 6648228-1 #8 AWG #8 1766484-1 #8 AWG #6 6648235-1 #4 AWG #8 6648239-1 #4 AWG #6 6648236-1 #4 AWG #4 6648238-1 #2 AWG #2 6648234-1 #2 AWG #0 1857547-1 12mm 95mm2 Current Rating Color* Black 50A Black Black Black 110A Black Black 150A Black Black 250A Red *Black, Red and Blue colors available Insulation Boots Socket Connectors - Straight Part No Size Color 1651003-1 #4 #8 Black 1651003-2 #4 #8 Red 1651003-3 #4 #8 Grey 1651003-4 #4 #8 Blue Type Size Plastic locking hood Wire Size Current Rating Color Part No #8 Black 1643279-1 Plastic locking hood #8 Red 1643279-2 Plastic locking hood #8 Blue 1643279-3 Socket contact #8 1766600-1 #2 Black 1766600-2 #2 Red Plastic locking hood #4 1766600-3 #2 Grey Socket contact #4 1766600-4 #2 Blue #8 50A 6648317-1 Black #4 120A 1651766-1 6648434-1 Part numbers listed are examples of some available samples, please visit website for additional and mating part numbers DATA AND DEVICES /// BUSBAR CONNECTIVITY PAGE 5 AMPOWER Wave Crimp System Features • Insulated flat copper cable conductors and associated interface components enable solutions to power distribution challenges through its unmatched packaging flexibility. • Variety of interfaces for end of cable or mid-cable terminations enable high application versatility and 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 round jacketed power cables or traditional busbars. • Fully touch-safe. Less copper compared to round jacketed cable; therefore less weight and lower cost per ampere of rated current. Copper Cable Options Part Number Width (mm [in1]) Thickness (mm [in1]) Copper Conductor(s) W (inch[mm]) x T (inch [mm]) Color Operating Voltage Max Current (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 MILS Approx AWG Amps Per Conductor DATA AND DEVICES /// BUSBAR CONNECTIVITY 12,566 9 80 5,729 13 40/40 25,133 6 110 11,459 10 55/55 PAGE 6 AMPOWER Wave Crimp System Cable-to-Cable Connectors Part Number Description Tail Type Tail Length (inch) 765191-1 slim plug N/A N/A 765478-1 slim receptacle N/A N/A 766569-1 cable to cable receptacle PM* N/A N/A 766569-1 PM needs: 765530-1, 765245-1 N/A N/A 766569-1 cable to cable receptacle STR** N/A N/A 766569-1 STR needs: 765529-1, 765245-1 N/A N/A Cable Receptacle PCB-Mounted Header *PM = Panel Mount **STR = Sqeeze-to-Release Blindmate PCB-Mounted Headers Mid-Cable Termination .250 FASTON Tab Tap PCB Mounted Headers Part Number Description Tail Type Tail Length (inch) 5765527-1 2 cable vert header Solder 0.131 5765527-2 2 cable vert header Solder 0.165 765608-1 2 cable R/A header Solder 0.273 5765208-1 4 cable vert header Solder 0.131 5765208-2 4 cable vert header Solder 0.165 5765208-3 4 cable vert header Solder 0.235 5765208-4 4 cable vert header Solder 0.305 766510-1 4 cable R/A header Solder 0.273 765208-5 4 cable vert header Press Fit 0.144 Part Number Description Tail Type Tail Length (inch) 1-765206-7 slim vert header Solder 0.131 1-765206-8 slim vert header Solder 0.165 1-765206-9 slim vert header Solder 0.225 2-765206-0 slim vert header with eyelet Solder 0.131 765271-1 slim vert header Press Fit 0.144 765204-5 slim R/A header Solder 0.124 765204-6 slim R/A header Solder 0.165 Blindmate Cable-Mounted Receptacles Mid-Cable Terminations Description Tail Type Tail Length (inch) 765528-1 2 cable housing N/A N/A 765528-1 needs: 765529-1, 765209-1, 768209-2 N/A N/A 765247-1 4 cable housing N/A N/A 765247-1 needs: 765248-1, 765209-1, 768209-2 N/A N/A Part Number Description Tail Type Tail Length (inch) Part Number 765277-1 Tap N/A N/A 765311-1 Side Tap, R/A N/A N/A 765275-1 Side Tap, Jogged N/A N/A 765276-1 .250 FASTON Tab Tap N/A N/A Terminal Block Interface Stud Interface Part Number Description Centerline [inch,(mm)] 765228-1 Full-Width Cover 765216-1 Termination Assembly, .562 0.562 (14.27) 0.171 x 0.250 (4.34 x 6.35) 765225-1 Termination Assembly, .688 0.688 (17.48) 0.270 x 0.296 (6.86 x 7.52) 765229-1 Half-Width Cover 765216-1 Termination Assembly, .562 0.562 (14.27) 0.171 x 0.250 (4.34 x 6.35) 765225-1 Termination Assembly, .688 0.688 (17.48) 0.270 x 0.296 (6.86 x 7.52) DATA AND DEVICES /// BUSBAR CONNECTIVITY Hole Size [inch,(mm)] Stud Size [inch,(mm)]) Hole Size [inch,(mm)] Termination Assembly for 1/4 0.250 (6.35) 0.266 (6.76) Termination Assembly for 5/16 0.312 (7.92) 0.328 (8.33) Part Number Description 765228-1 Cover 765226-1 765226-2 PAGE 7 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/busbar © 2020 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 02/2020 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 adjustments to the information contained herein at any time without notice. TE expressly disclaims all implied warranties regarding the information contained herein, 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