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PowerWize Connectors

High-Power Solutions

PowerWize Connectors

Leveraging its advanced COEUR socket technology, the PowerWize Interconnect System is designed to meet the demanding needs of modern high-power applications. These connectors feature innovative multiple contact beams, resulting in exceptionally low contact resistance and minimal voltage drop. PowerWize Connectors deliver enhanced current-carrying capacity and reduced heat generation, ensuring manufacturing flexibility and reliable performance.

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Current Contact Diameter Operating Temperature
up to 190.0A 3.40, 6.00 and 8.00mm -40 to +125°C

PCB Headers

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PowerWize PCB Header

Connector Housings

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PowerWize Receptacle Housing

Crimp Terminals

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PowerWize Crimp Socket

Connector Accessories

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PowerWize Terminal Position Assurance Retainer

Cable Assemblies

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PowerWize Cable Assembly

Features and Benefits

Power efficiency is critical to cost management in large power-consuming operations such as data centers and telecom central offices. PowerWize crimp contacts with COEUR socket technology, offer low contact resistance and low voltage drop at the contact interface. Due to its multiple contact beams, this technology allows designers to design-in a high-current capable wire-to-board and wire-to-busbar system that reduces heat generation and enables higher current-carrying capacity compared to other contact designs.

For energized equipment, such as a server or a power supply array, safe handling is required when installing new devices or removing defective machinery.  PowerWize headers and receptacles are designed to comply with industry-standard touch-safe requirements, helping to protect users. Operators can avoid accidentally shocking themselves when mating or un-mating cable assemblies built with these connectors.

Designers are often challenged with identifying high-power, wire-to-board or wire-to-busbar interconnects that can be attached to various substrates and crimped to different wire styles and gauges. PowerWize Connectors offer screw-mount headers that attach to either printed circuit boards or busbars and provide crimp sockets that accept 10 to 1/0 AWG wires. With a single, versatile wire-to-board and wire-to-busbar product family, designers can address a wide range of application-specific requirements.

Low Contact Resistance

The COEUR conical socket’s multiple contact beams offer low contact resistance and low voltage drop so there is minimal heat generation at the contact interface. This leads to a higher current-carrying capacity compared to other contact options.

6mm COEUR Socket

Secure Mating

Positive locking headers and receptacles provide tactile and audible feedback during system integration, allowing for secure mating. This helps prevent cable assemblies from disengaging headers due to shock vibration or mishandling.

3.4mm PowerWize Receptacle

Mechanically Keyed, Color Coded

Headers and receptacles are mechanically keyed to eliminate mismating during system integration. Additionally, the 6.00mm connectors are also color-coded to facilitate faster system integration when multiple connectors are used on an application.

PowerWize Wire-to-Board Headers

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.

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.