Power ProductsPresented by: Bill Kysiak

bkysiak@hirose.comAugust , 2015

HIROSE ELECTRIC U.S.A.

WebEx will be recorded for future viewing

5A 50A 100A30A 300A150A20A

PS2Plug-in

I/O

Service Plug

Board-to-Board

Board-to-WireWire-to-Wire

PS2 PS2

EM35M

200A

EM35WEV1

PQ50S

DF60DF22

DF33/33C

FX30B

QR/P

LF

HR30 RM

PS3

EF1

HR41

HR41A

JR

MDF6

RM-W

IT-P

EM30MSD

DF63

HR34B

DF5

PQ50W

Water-Proof Non-Water-Proof

PQ50W ＴHR43

JR-W

GT28

DF64

DF61

H/MS

EM12M

PQ50

3

Products for todays discussion

HR41 HR41A PS3C EM12 PS2 PS3 PS3F EM30MSD PS4

Power Products

4

Power ProductsHR41

IP68 Power Connectors Suitable for Harsh Environment

Flange Type (3 pos.) Bulkhead Type (5 pos.)

1. IP68 weather-resistant waterproof connector for outdoor use2. User-friendly bayonet lock and tactile plug alignment indication3. Higher lightning surge protection (15 kV) and withstanding voltage4. Sequential contact structure for hot swap5. Easy field assembly with market commodity crimp tool6. Anti-loosening mechanical structure for clamp tightening 7. Will be safety standards certified (UL certified, TÜV pending)

5

Power ProductsHR41

2000 hours of Sunshine Weather TestLight-weight & corrosion-resistant plastic body, yet robust designPassed 1500 hours of salt spray test

15 kV of Lightning Surge Protection

IP68 WaterproofNo water intrusion, while submerged in 2 m water depth for 14 days in mated condition.

Power ProductsHR41

3 position

(93)

19 27

4

□36.4

φ 3

7.5

(100) 3

2.3

Plug

Receptacle

Jack

7

Power ProductsHR41

(94)

37

.5

51

(48.3)

Receptacle Plug

Plug CapReceptacle Cap

Waterproof Cap (Common for both types)

5 position

8

Power ProductsHR41

Long Creepage Distance

Housing Walls

GND

Signal Signal

Housing Grooves

Pin assignment for 3 pos to maintain maximum lightning surge protection.

High lightning surge protection: 15 kV

9

Power ProductsHR41

Sequential Mating Structure2 Step for 3 position; 3 step for 5 position

Signal

1

2

3

5

4

GND

Signal

Power

Signal

Power

3GND

1Signal

2Signal

[3 pos.]

GND

Power

Signal

1st Contact:

2nd Contact:

3rd Contact:

GND1st Contact:

2nd Contact:

[5 pos.]

10

Power ProductsHR41

Stepped Contact Points for Hot Swap 2nd contact is protected from the arc generated during hot swapping.

Arc is generatedby hot swapping!

11

Power ProductsHR41

IP68 Waterproof. No water intrusion submerged in 2 m water depth for 14 days in mated condition.

Waterproof gaskets are built in at each joint, preventing water intrusion into the connector.

3 pos. 5 pos.

12

Power ProductsHR41

Hirose’s unique clamping structure

- Cable sealed and clamped at once by tightening ring

- Firmly clamped over gasket

- Plastic is used at clamp area

Tightening ringGasket

Shell

Cable

Clamp

Securely clamped

Sealed with waterproof gasket

Simplified assembly

Strengthened cable retention force

Light weight

13

Power ProductsHR41

Application Examples

LED Lighting

BTS

Robotaround Water

Lighting in Harsh Environment

Fishing LightLight for Construction Field etc.

Street LampTunnel Lighting etc.

ETC System

14

Power ProductsHR41A

IP68 Small Plastic Power Connector

1. IP68* weather-resistant waterproof connector for outdoor use2. Higher lightning surge protection (15 kV) and withstanding voltage3. Snap-in mating with user-friendly push-on bayonet lock 4. Bayonet assembly eliminates torque management and re-tightening.5. Easy field assembly6. UL, TÜV pending

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Power ProductsHR41A

Receptacle Plug

Jack

Small and Light Weight

65.8

φ1

6.8

φ2

4.6

41.2

φ1

9.8

φ2

1.0

74φ

21

.0

Light Weight with Plastic Shells

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Power ProductsHR41A

Long creepage distance is provided by isolated contact with housing walls

Lightning Surge Protection

Housing Walls Housing Groove

Receptacle Plug

Resistant to 15kV Impulse Voltage by Induced Lightning

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Power ProductsHR41A

Push on Bayonet lock Structure

Mating

Unmating

Un-mate by Rotating the sleeve to either right or left to

release the lock.

Easy one-step mating push the plug straight

into the receptacle.

Rotate

Push

Pull

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Power ProductsHR41A

Water proof gaskets and O-ring at each join prevents water intrusion into the connector.

IP68 WaterproofNo water intrusion, while submerged in 2m water depth for 14 days in mated condition.

Suitable for outdoor applications!

19

Power ProductsHR41A

(1)Cable is sealed and clamped at once by tightening ring

　　 Simplified Assembly

(2) Firmly clamped over gasket 　　 High cable force retention

(3) Plastic is used at clamp area 　　 Light Weight

Sealed with waterproof gasket

Securely clamped

Shell Gasket PlasticClamp

Tightening ring

Cable

Easy assembly with excellent water resistance

Power Products

PDUPower Distribution Units

Low Voltage Switch gears

Inverters

High Voltage (100kV’s)Substation switchgear

Energy Storage Systems

UPSUninterrupted Power Systems

PowerStorage

PowerDistribution

21

Power ProductsHRS Connector Solutions for Storage BatteriesFront Cable Connection

Rich connector variations for each battery connection systems

EM12M

DF60

PS3C

19 inch rack

Plug-in Connection

PS2

PS3

PS3F

22

Power ProductsPS3C

High Current Single Pos. Cable Connector supporting 150 Amps for Storage Battery

1. Rated up to 150 Amps 2. 180 reversal mate allows flexible cabling3. Downsized receptacle saves space inside battery unit.4 ． Right angle plug saves space for cable wiring5 ． Supports the use of hard lock nut , eliminating the re-tightening process of male contact connection. 6 ． Safety design with IP2X finger protection7 ． Guide key and color coding prevents mis-mating between plus and minus electrode.8 ． Will be UL, C-UL, TÜV certified

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Power ProductsPS3C

Receptacle Plug　　

36.9

58.5

52.2

MAX. 20

54.35

41.2

72.6

35.75

Small receptacle contributes to saving occupied area inside the battery unit.

PS3C Other’s

Area 32 % Reduced

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Power ProductsPS3C

High Reliability Contact Design

Blade contact structure realizes high current capability with small design.

1) Highly reliable clipping contact design with bellows contact.2) “Contact area” x “Multi contact point” suppresses contact resistance and allows high current flow.

Male Contact(Plug Side)

Female Contact(Receptacle Side)

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Power ProductsPS3C

Simple Assembly Process

No special tool is required, which allows field assembly.

Receptacle

Plug

Screw Down at 1 point

Screw Down at 1 point

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Power ProductsPS3C

Flexible Cabling Directions

PC3C allows flexible cabling directions, supporting various battery unit layout

Vertical Battery Placement

Flat Battery Placement

180 reversal mate

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Power ProductsPS3C

Mis-Mating Prevention

Receptacle Plug

Both the keys and the colored housing avoids possible mating error

Mating Groove Mating Key

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Power ProductsEM12

Single Pos. Snap-in Lock Power Connector up to 90 Amps

1 ． Supports 90 Amps2 ． Quick and secure snap-in inertia lock3 ． Safety design with finger protection4 ． Crimp termination with commercially available crimp

tool.5 ． Keying and colored housings prevents mis-wiring6. TÜV, UL certified

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Power ProductsEM12

37.9

28.4

72.8

68.5

33.5

31

Receptacle PlugMated

42

61

30

Power ProductsEM12

Audible tactile “click” prevents incomplete mating.

Unlock Lever

Mate

Plug

Receptacle

Mating　　 Push in the plug.

Un-mating　　 Depress unlock lever and pull plug from receptacle.

Snap-in Lock for Safety Operation

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Power ProductsEM12

Crimp terminal in the plug. Applicable cable is 22mm2 size

Receptacle Plug

Commercially available crimp terminal on receptacle

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Power ProductsEM12

Receptacle

Plug

Mating Key

Mating Groove

Mating key and colored housing prevent mis-wiring in multiple use

OK

×

Key A Key B

OK

×

Mating Keys for Multiple Use

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Power ProductsEM12

Storage BatteryPower Controller

Inverter

Robot Controller

Medical Equipment

BTSUPS

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Power ProductsPS2

Plug-In Connector for Storage Battery Available in 100 / 200 / 300 Amp contacts

1. Hybrid power / signal contact design2. Floating screw allows 2.5 mm floating mate3. Reliable crimp method for wire termination of signal

contact4. Multiple power contact springs improve current

carrying capacity.5. Sequential contacts detect incomplete mating for

safety6. Finger protection cap is provided7. UL pending

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Power ProductsPS2

Step1:Install battery modules

Step2:Wiring

Step3:Plug-in battery modules

Completed

Step1:Connector assembly

Step2:Wiring

In a factory

In a factory

On site

Completed

Storage Battery Connection -Installation Efficiency-

Operation process is reduced and worker’s safety is improved.

New

S

yste

m

System rack assembly

On site

[1] Cable wiring on site is eliminated. [2] Risk of touching electrical lines is reduced.

Co

nve

nti

on

al

Sys

tem

36

Power ProductsPS2

Step1: Remove cables

Step2:Plug-in battery

module

Step3:Install battery

module

Step4:Wiring

Step1:Remove battery

module

RemovalReplace battery Installation

Removal Replace battery Installation

Old battery

New battery

Old battery

New batteryCompleted

Completed

-Maintenance Ease-

Co

nve

nti

on

al

Sys

tem

New

Sys

tem

Maintenance efficiency is drastically improved.

Step2:Remove battery module

37

Power ProductsPS2

200 AmpModule

Module sideSystem Rack side

System Rack

120

135

34

49

(13

.5)

33

.1

Power contact Signal contact

(136.9)

152.4

22

.86

0(2

1.3

)Power contact Signal contact

Cap for finger protection (IP2X)

38

Power ProductsPS2

Easy Signal Contact Installation

Power contacts are connected to BUS bar. Also, cable connection is acceptable by using standard crimp contact.

BUS bar

Screw*

Power contacts are connected to cables with screws.

Screw*

Module side

System rack side

1. Insert the crimped signal contact into the housing.

2. Install the connectorized crimped contacts in the housing into the connector body.

Connection to the Power Contacts

39

Power ProductsPS2

Floating screw

Floating Structure

Absorbs misalignment during mating in X and Y directions up to 2.5 mm.

Clearance

Attached

Floating structure supports easy plug-in connection.

X -2.5

X +2.5

Y+2.5

Y-2.5

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Power ProductsPS2

Reliable Contact Structure

Multiple Contact Points

Mated

Multiple contact springs

Multiple contact springs decreases contact resistance and achieves high current capability. Also provides a secure contact under vibration.

Multiple contact points enables high current capability and endures reliability use in harsh environments.

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Power ProductsPS2

Sequential contacts are utilized to detect mating conditions

1st power, 2nd signal contacts

Sequential Mating Structure

First Mate

Second Mate

1. Power Contacts 2. Signal Contacts

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Power ProductsPS3

Plug-In Connector for Storage Battery Capable up to 150 Amps

1. Rated up to 150 Amps2. Floating screw allows 2 mm floating mate.3. Slim design achieved by employing unique blade contact allows application to

standard 1U rack.4. Cable connection to power contact is done by screw fixation.5. Finger protection meeting IP2X requirements contributes to operators’ safety. 6. Dust cap is available.7. Will be UL, C-UL, TÜV certified* (Power type is already certified)

*Conditions for safety standards vary depending on submitted applications of current and voltage ratings. Contact Hirose for details.

Power Type Power / Signal Hybrid Type

43

Power ProductsPS3

Battery Module SideSystem Rack Side　

9.2

43

.52

2.7

124.6

23

41

.8

131.7

39

.71

4.7

5

12

.75

Slim design allows mounting to standard 1U rack (44.5 mm x 482.6 mm)

Connector Dimensions (Power only Type)

44

Power ProductsPS3

43

.52

2.7

198.6

9.2

23

41

.8

205.7

39

.71

5

12

.75

Connector Dimensions Power / Signal Hybrid Type

Battery Module Side　　

System Rack Side　　

Slim design allows mounting to standard 1U rack (44.5 mm x 482.6 mm)

45

Power ProductsPS3

Blade contact structure allows low profile connector

Male Contact(System Rack Side)

Female Contact(Battery Module Side)

1) Highly reliable clipping contact design with bellows contact.

2) “Contact area” x “Multi contact point” suppresses contact resistance and allows high current carrying.

High Reliability Contact Structure (Power Contact)

46

Power ProductsPS3

GT8E connector used for Signal Contacts. Proven use in Automotive Market

Two connector types with 12 pos. & 16 pos. prevents mis-mating

GT8E 16 pos.

GT8E 12 pos.

47

Power ProductsPS3

Floating Screw

X -2.0

X +2.0

Y+2.0

Y-2.0

Attached

M6 x 1.0

5.5

Floating StructureUsing floating screws absorbs misalignment during mating in X and Y

directions up to 2 mm.

Floating structure supports easy plug-in connection

48

Power ProductsPS3F

Power / Signal Hybrid 100 Amps Power Supply, Front Access Plug-in Connector

1. ”Front Access” on system rack side allows cable assembly from mating side.2. Front access is best suited to the systems with no space at the back side for maintenance.

49

Power ProductsPS3F

Ideal design for batteries installed inside containers

PS3F allows power/signal cables attachment/ detachment from the plug-inside (front side). Optimum for systems installed closely to the container wall etc. with no maintenance space at the back face.

No maintenance space

Inaccessible from the system back side

All the operations can be done from the battery side

50

Power ProductsEM30MSD

(Manual Service Disconnect)

Service Plug supporting 200 Amps

1 ． 200 Amps capability with small size2 ． Signal contact with interlocking switch to detect mating status3 ． Shock resistant multi-contact & bayonet lock systems4 ． IP68* water resistant5 ． Commercially available crimp terminal is applicable6 ． Safety design with IP2X finger protection7 ． UL, C-UL, TÜV pending

51

Power ProductsEM30MSD

What’s “Service Plug”?Physically interrupts the electric circuit and protects operators from high voltage shock accidents.

Plug Removal

MatedPower LineSignal Line

52

Power ProductsEM30MSD

(110)

(35.6)(27.9)

(50)

Small Size & Light Weight

Receptacle Plug(φ46.2)

(44.4)

53

Power ProductsEM30MSD

Reliable Multiple Contact Points

Receptacle Power Terminal

- Multiple contact point controls the contact resistance, allowing high current capacity.

- Excellent performance in Vibration applications

Plug Power Terminal

54

Power ProductsEM30MSD

Interlocking SwitchBy rotating the plug, signal lines are switched ON and OFF. Signal lines are always switched in the “OFF” position prior to the plug removal.  This will avoid a hot swapping condition.

Lock Status:

Power Line:Signal Line:

Plug insertion/before rotation

ConnectedDisconnected (OFF)

Rotating for lock

ConnectedConnected (ON)

Fully locked

ConnectedConnected (ON)

Plug side Signal Contact

Plug Side LockReceptacle Side Lock

55

Power ProductsEM30MSD

Waterproof Structure IP68

No water intrusion, while submerged in 2 meter water for 14 days.

56

Power ProductsEM30MSDApplications

Hybrid BusStorage Battery

Construction Machinery

57

Power ProductsPS4

Hirose New Floating Bus-Bar Connector

Release date TBD

250 A (Tentative)

58

Power ProductsPS4

THANK YOU.