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PowerWize BMI Connectors

High-Power Solutions

PowerWize BMI Connectors

PowerWize BMI blind-mating panel-to-board / panel-to-busbar connectors incorporate Molex’s COEUR socket technology, which helps ensure low contact resistance at the mating interface to minimize heat generation and enable, high current-carrying capacity. It is available in three sizes: 3.40mm (75.0A), 6.00mm (110.0A) and 8.00mm (185.0A). The blind-mating design helps ensure accurate mating in hard-to-reach and visually obscured spaces.​

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 Current Rating  Contact Diameter  Operating Temperature
up to 185.0A 3.40, 6.00, 8.00mm -40 to +125°C

PCB Headers

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PowerWize BMI PCB Header

Connector Housings

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PowerWize BMI Receptacle Housing

Crimp Terminals

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PowerWize BMI Crimp Socket

Connector Accessories

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PowerWize BMI TPA Retainer

Features and Benefits

Power efficiency is critical to cost and safety management in power intensive applications including power transmission systems in datacenters, base stations, battery management and inverters. PowerWize BMI Connectors incorporate Molex’s proven COEUR socket, which has multiple contact beams to create a large contact surface at the contact interface, resulting in very low contact resistance. The voltage drop across the contact interface is very low with minimal heat generation.

Dense electronic packaging often requires designs where subassemblies are mated without visual guidance, such as drawer style applications. PowerWize BMI Connectors are designed for blind-mating situations. Guide rails engage before the electrical components to help ensure gross alignment and the panel mount housing flanges allow +/- 2.00mm of radial self-alignment to mitigate tolerance stack-up issues.

Identifying high-power wire-to-board/busbar interconnects that can be attached to a wide range of substrates and crimped to a wide range of wire gauges. PowerWize BMI screw-mount headers can attach to either printed circuit boards or busbars and PowerWize BMI solder tail headers attach to printed circuit boards. PowerWize BMI crimp machined contacts offer a wide range of wire gauges including 1/0, 2, 4, 6, 8, or 10 AWG wires.

Blind-Mating/Self-Aligning Connectors

The panel-mounted receptacle housing’s guideposts align with the inner surfaces of the header sidewalls before the female contacts and male pins engage, facilitating trouble-free blind mating. When mounted to the panel (using either shoulder bolts or force-fit stand-offs), the cable assembly has +/- 2.00mm of radial self-alignment, mitigating tolerance stack-up issues.

PowerWize BMI Panel Mount Receptacle

Low-Contact Resistance

The COEUR conical socket offers low-contact resistance and low-voltage drop so there is minimal heat generation at the contact interface, resulting in higher current-carrying capacity compared to other contact designs.

COEUR Socket

Reflow and Wave Solder-Capable Headers

The reflow-capable/wave-solder-capable solder tail headers are suitable for either pin-in-paste reflow PCB processing or wave-solder PCB processing, providing enhanced manufacturing flexibility.

PowerWize BMI Connectors

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

Reliable crimp geometry eight-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 in higher current-carrying capacity compared to other designs

Terminal backout assurance
Provides two (opposed) positive locks that hold the TPA retainer securely to the blind-mate receptacle housing silo
Helps prevent the crimp contact from backing out of the receptacle with six beams robustly holding the crimp contact inside the TPA retainer

Reflow and Wave Solder-Capable Headers
The reflow-capable/wave solder-capable solder tail headers are suitable for either pin-in-paste reflow PCB processing or wave solder PCB processing, providing enhanced manufacturing flexibility.

Optimal current-carrying capacity with multiple contact beams
Provides low contact resistance, low voltage drop and minimal heat generation at the contact interface.

Screw-mount pins attached to both printed circuit boards and busbars; solder tail pins attached to printed circuit boards
Offers options to attach pins to different substrates for design and manufacturing flexibility.

User-friendly cable assembly build
The contact is crimped to the stripped wire. The TPA retainer slips completely over the crimped contact and its beams are positioned against the rear of the contact flange.
The subassembly is then inserted into one of the panel mount housing silos with the TPA retainer locking into place and generating mechanical feedback and an audible click to help ensure the crimped lead contact is fully engaged and minimizes the opportunity for terminal blackout.

Low Contact Resistance
The COEUR conical socket offers low contact resistance and low voltage drop so there is minimal heat generation at the contact interface, resulting in higher current-carrying capacity compared to other contact designs.

Secondary substrate attachment
Achieves additional board retention (if desired) by attaching the right-angle header to the substrate using M3 bolts, nuts and the two mounting flanges molded into the body of the header.

Crimp contacts available to accept a wide range of wire gauges (10 AWG to 1/0 AWG)
Provides design and manufacturing flexibility.

Blind-mating/Self-aligning Connectors
The panel-mounted receptacle housing’s guideposts align with the inner surfaces of the header sidewalls before the female contacts and male pins engage, facilitating trouble-free blind mating.
When mounted to the panel (using either shoulder bolts or force-fit stand-offs), the cable assembly has +/- 2.00mm of radial self-alignment, mitigating tolerance stack-up issues.

Mechanically Keyed
The panel-mount receptacle housing and the panel cutout are mechanically keyed to prevent attachment of cable assemblies to the panel upside down.

Applications by Industry

Electric vehicle charging stations: Inverters

Battery Storage System
Gateway Storage System

Data storage units
Enterprise switches
Environmental control equipment
PDUs (Power Distribution Unit)
Power shelves
Servers
Uninterruptable power supplies

Data storage units
Network routers
PDUs (Power Distribution Unit)
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

My design has unique space constraints that limit the height that the receptacle assembly can extend above the surface of my printed circuit board (or busbar). What is the mated height of the PowerWize BMI solution?
The nominal mated height of the 3.40mm PowerWize BMI solution is 17.45mm. For the 6.00mm PowerWize BMI solution, the mated height is 22.10mm, while for the 8.00mm PowerWize BMI solution, the mated height is 24.10mm.

How are the PowerWize BMI components packaged?
The receptacle housings and their TPA retainers are bag-packed into cartons. The crimp contacts and headers are tray-packed inside of cartons.

I am interested in purchasing a cable assembly with PowerWize BMI connectors on both ends, rather than buying individual PowerWize BMI receptacle housings, TPA retainers and crimp contacts. Is Molex able to design and build double-ended PowerWize BMI cable assemblies?
Yes. Molex has a business segment that designs and builds cable assemblies. Contact your local Molex sales representative for details.

I am interested in purchasing a cable assembly with a PowerWize BMI connector on one end a non-Molex connector on the other end. Is Molex able to design and build cable assemblies with a PowerWize BMI receptacle housing on one end and a competitor’s connector on the other end?
Yes. While we love it when both ends of a cable assembly use Molex connectors, we understand that is not always the best solution. Molex has a business segment that designs and builds cable assemblies with a PowerWize BMI connector on one end and another manufacturer’s connector on the other end. Contact your local Molex sales representative for details.