The product information in this catalog is for reference only. Please request the Engineering Drawing for the most current and accurate design information. All non-RoHS products have been discontinued, or will be discontinued soon. Please check the products status on the Hirose website RoHS search at www.hirose-connectors.com, or contact your Hirose sales representative. NEW High-Current Connectors PS Series 2 Types of Power Contacts plus Signal Contacts Plug Receptacle ■Overview High quality connectors combining two different current capacity power contacts and signal contacts, allowing power connections and signal control between power rectifier units. ■Features 1. Sequential power connection Power contacts can be arranged to connect in 3-stage sequence (Fig. 1) 2. Live line connection (low current contacts) Connectors can be mated / un-mated with power applied through the low current contacts. Safety rated at 35 A, 120 V (50 insertions/removals). High-current contacts High-current power supplies Signal contacts Signal sections Low-current contacts Low-current power supplies Current Capacity of the contacts Contact High-current contacts Signal contacts Low-current contacts Remarks Wire size Current Capacity AWG# 0 150A AWG# 4 100A AWG# 0 200A * With bus bar AWG# 4 150A * With bus bar AWG# 20~22 2.5A AWG# 24 2A AWG# 8 50A ------------- ------------------------- 40A AWG# 10 * Current capacity has been established during the testing. Contact Hirose Electric when using the bus bar for higher current capacity applications. 3. Protection against contact deformation Below-configured signal contacts will not deform during mating of the connectors. 3-Stage Sequential contact engagement 4. Crimp termination Contact: Long Crimp termination of the conductors for the Low current and Signal contacts. 1.2mm Contact: Short 5. Threaded termination 1.2mm Threaded termination with a separate crimp ring terminal, spring washer and M6 screw for the High current contacts. Terminal: Long 1.2mm Contact: Short 6. Self-alignment when mating Increased self-alignment within ± 0.5mm, with the use of Floating Screws to mount the plug or receptacle assemblies. Fig.1 Current Capacity Ratings in Various Safety Standards Wire size ■Applications Uninterruptible power supplies (UPS), power supplies for base stations, electric cars, power supplies of semiconductor manufacturing machines, electrical generators and other large-current power supplies. High-current contacts Signal contacts Low-current contacts UL C-UL TÜV AWG 0 150A-125V 150A-125V 150A-125V AWG 0 + Bus bar 200A-125V 200A-125V 200A-125V AWG 4 100A-125V 100A-125V 100A-125V AWG 4 + Bus bar 150A-125V 150A-125V 150A-125V AWG 20~22 2.5A-125V 1.5A-125V 2.5A-125V AWG 24 2A-125V 1A-125V 2A-125V AWG 8 50A-600V 40A-600V 50A-600V AWG 10 40A-600V 30A-600V 40A-600V Insertion and removal of live wires: 35 A - 120 V, 50 cycles 2006.3 1 The product information in this catalog is for reference only. Please request the Engineering Drawing for the most current and accurate design information. All non-RoHS products have been discontinued, or will be discontinued soon. Please check the products status on the Hirose website RoHS search at www.hirose-connectors.com, or contact your Hirose sales representative. ■Product specifications Operating temperature / humidity range -55ç to +125ç / relative humidity 90% max. (Note 1) Storage temperature / humidity range -55ç to +185ç / relative humidity 95% max. (Note 2) Voltage rating Ratings 125V AC/DC 200A(AWG #0) With bus bar (High-current contacts) Current rating 150A(AWG #0) Without bus bar 150A(AWG #4) With bus bar 100A(AWG #4) Without bus bar Operating temperature / humidity range -55ç to +125ç / relative humidity 90% max. (Note 1) Storage temperature / humidity range -55ç to +85ç / relative humidity 95% max. (Note 2) Ratings Voltage rating (Low-current contacts) Current rating 600V AC/DC 50A (AWG#8) 40A (AWG#10) Operating temperature / humidity range -55ç to +125ç / relative humidity 90% max. (Note 1) Storage temperature / humidity range -55ç to +85ç / relative humidity 95% max. (Note 2) Ratings (Signal contacts) Voltage rating Current rating 125V AC 2.5A (AWG#20~22) 2A (AWG#24) Note 1: Includes temperature rise caused by current flow. Note 2: The term “storage” refers to products stored for long period of time prior to mounting and use. Operating temperature range and humidity range covers non-conducting condition of installed connectors in storage, shipment or during transportation. ■Materials/Finish Component Housing Material Finish/Color Remarks PBT Black UL94V-0 Copper alloy High-current contacts Low-current contacts Signal contacts 2 Stainless steel (Stop ring) Copper alloy Gold plated (Contact area) ------- Gold plated (Contact area) ------- Gold plated ------- Stainless steel (Stop ring) Copper alloy The product information in this catalog is for reference only. Please request the Engineering Drawing for the most current and accurate design information. All non-RoHS products have been discontinued, or will be discontinued soon. Please check the products status on the Hirose website RoHS search at www.hirose-connectors.com, or contact your Hirose sales representative. ■Ordering Information 1. Housing PS 1 - 4 U 32 D / 6 Q P 1 2 4 5 4 5 4 Output side Series name: PS Series ID: 1 Housing type: 4 5 Number of contacts Contact size D : 3A current N : 40A current Q : 50A current U : 150A current Contact type: P : Male contact S : Female contact Terminal type: C : Crimp J : Screw clamp Contact type: 1 : Stamped, loose 3 : Machined, loose Plating specification: 1 : Gold plated Contact length: A : Standard (Short) B : Sequenced (Long) FS : Floating screw DC : Dust cover PT : Partition 3 Input side 2. Contact 6 7 PS - P A C - 3 N 1 1 5 1 2 3 10 6 7 8 5 9 8 9 10 3. Floating screw 11 12 13 PS - FS 1 P : Plug, for male contact S : Receptacle, for female contact 11 4. Dust cover PS 1 - DC 1 2 12 5. Partition PS 1 - PT 1 2 13 3 The product information in this catalog is for reference only. Please request the Engineering Drawing for the most current and accurate design information. All non-RoHS products have been discontinued, or will be discontinued soon. Please check the products status on the Hirose website RoHS search at www.hirose-connectors.com, or contact your Hirose sales representative. ■Plug housing ●4 High Current contacts, 6 Low current contacts, 32 Signal contacts Part number CL No. RoHS PS1-4U32D/6QP CL236-1000-2 YES (42.9) 31.4 50 2-8.89 108 98.29 6 (51) BShown panel mounted and mated with corresponding part BPanel cutout Viewed from the front 38~40 Receptacle PS1-4U32D/6QS Plug PS1-4U32D/6QP 89 33 53 4 R1 4- Panel 98.29 Panel M5∞0.8-2 Thread R5 .45 The product information in this catalog is for reference only. Please request the Engineering Drawing for the most current and accurate design information. All non-RoHS products have been discontinued, or will be discontinued soon. Please check the products status on the Hirose website RoHS search at www.hirose-connectors.com, or contact your Hirose sales representative. ■Plug housing ●Low current, 2 contacts Part number CL No. Packaging RoHS PS1-2QP CL236-1020-0 Bag (10 pieces / bag) YES 47 37.3 24.5 PS1 >PBT< 9 R4 .5 Refer to Page 6 for contacts (PS-PAC-3*1). 6 23.5 26.6 31.4 BShown panel mounted and mated with corresponding part Commercially available screw 19.6 BPanel cutout Viewed from the front PS-FS Screw R1 .6 37.3 MA X 28.6 8.1 M5 ∞0 .82 R7 X 25.6 Commercially available screw Panel MA 24.6 PS1-2QP Plug PS1-2QS Receptacle PS-FS Screw 38~40 Panel 5 The product information in this catalog is for reference only. Please request the Engineering Drawing for the most current and accurate design information. All non-RoHS products have been discontinued, or will be discontinued soon. Please check the products status on the Hirose website RoHS search at www.hirose-connectors.com, or contact your Hirose sales representative. ■Male contacts for Plug ●High current 11(Effective thread length) 13 M6∞1-2 .8 Ø15 Ø10 12 13 Ø12.4 .8 A .4 Ø6 A PS-PAJ-3U1 CL236-1002-8 30.7 PS-PBJ-3U1 CL236-1003-0 31.9 Packaging RoHS Bag (5 pieces / bag) YES 16.8MAX. CL No. .8 ~8 Part number Ring crimp terminal dimensions Fig.1 Note 1: To terminate with recommended wire (stranded conductor nominal cross section: 42.2 to 60.57 mm_) use non-insulated barrel ring crimp terminal (as shown in Fig. 1). Example of the ring crimp terminal: P.N 60-S6, manufactured by J.S.T. MFG. Co., Ltd. Verify the correct current rating of the ring terminal and required crimp dimensions with the terminal manufacturer. Note 2: The contact is terminated with M6 x1-2 (JIS B 1188) screw (nominal thread length of 12mm) with corresponding size spring washer. Recommended tightening torque:400 to 490 N•cm. In high vibration environments it is recommended to use thread-locking compounds. Note 3: The terminal extraction tool (PS-PA(B)J-3/REMD CL902-2115-0) is available separately. ●Low current Ø3.2 B C Ø9.4 Ø5.8 10.5 (For4.6 mm dia. hole) 9.5 1-Ø2 (Conductor insertion verification hole) (6.5) (1) 13 A (Conductor crimp area) Part number CL No. A B C PS-PAC-3Q1 CL236-1004-3 26 Ø4.6 Ø7 PS-PAC-3N1 CL236-1013-4 26 Ø3.5 Ø5.5 PS-PBC-3Q1 CL236-1005-6 27.2 Ø4.6 Ø7 PS-PBC-3N1 CL236-1014-7 27.2 Ø3.5 Ø5.5 Conductor cross section (AWG#) JIS applicable crimp size 6.64~10.52mm (AWG #18) 2 2.63~6.64mm2 (AWG #10) 6.64~10.52mm2 (AWG #18) 2.63~6.64mm2 (AWG #10) Packaging RoHS Bag (10 pieces / bag) YES 8 5.5 8 5.5 Note 1: Verify that the conductor remains fully inserted and visible through the 2mm dia. hole after crimping Note 2: The terminal extraction tool (PS-PA(B)C-3/REMD CL902-2116-2) is available separately. Packaging RoHS PS-SAC-1D1 CL236-1006-9 Bag (100 pieces / bag) YES Note 1: Applicable wire AWG #20 to 24. Note 2: Crimping tool: HT201/PS-SC Note 3:The terminal extraction tool (PS-P(S)AC-1/REMD CL902-2119-0) is available separately. 6 15.9 A CL No. 2 Part number 2.7 ●Signal The product information in this catalog is for reference only. Please request the Engineering Drawing for the most current and accurate design information. All non-RoHS products have been discontinued, or will be discontinued soon. Please check the products status on the Hirose website RoHS search at www.hirose-connectors.com, or contact your Hirose sales representative. ■Receptacle housing ●4 High Current contacts, 50 2- 8.89 8 (41.45) 24.1 6 108 98.29 6 Low current contacts, 32 Signal contacts Part number CL No. RoHS PS1-4U32D/6QS CL236-1001-5 YES 8 BShown panel mounted and mated with corresponding part BPanel cutout Viewed from the front 38~40 M5∞0.8-2 Panel Panel (45.25) 1 Receptacle PS1-4U32D/6QS 89 98.29 4-R Plug PS1-4U32D/6QP 53 ●2 Low current contact 15.2 38.1 26.6 (19.2) .2 Ø5 Part number CL No. Packaging RoHS PS1-2QS CL236-1021-2 Bag (10 pieces / bag) YES BShown panel mounted and mated with corresponding part Commercially available screw BPanel cutout Viewed from the front PS-FS Screw R1 .6 37.3 MA 28.6 8.1 M5 ∞0 .82 X R7 MA 24.6 PS1-2QP Plug PS1-2QS Receptacle X 25.6 Commercially available screw Panel 37.3 47 1 2 (20.2) PS1 >PBT< 6 PS-FS Screw 38~40 Panel 7 The product information in this catalog is for reference only. Please request the Engineering Drawing for the most current and accurate design information. All non-RoHS products have been discontinued, or will be discontinued soon. Please check the products status on the Hirose website RoHS search at www.hirose-connectors.com, or contact your Hirose sales representative. ■Female contacts for Receptacle ●High current 11 (Effective thread length) M6∞1-2 13 .8 Ø15 Ø12.4 .8 12 13 29.9 CL No. Packaging RoHS PS-SAJ-3U2 CL236-1007-1 Bag (5 pieces / bag) YES Ø6 . Part number 4~ 16.8MAX. Ø8 .8 (41.9) Note 1: To terminate with recommended wire Ring crimp terminal dimensions Fig.1 (stranded conductor nominal cross section: 42.2 to 60.57 mm_) use non-insulated barrel ring crimp terminal (as shown in Fig. 1). Example of the ring crimp terminal: P.N 60-S6, manufactured by J.S.T. MFG. Co., Ltd. Verify the correct current rating of the ring terminal and required crimp dimensions with the terminal manufacturer. Note 2: The contact is terminated with M6 x1-2 (JIS B 1188) screw (nominal thread length of 12mm) with corresponding size spring washer. Recommended tightening torque:400 to 490 N•cm. In high vibration environments it is recommended to use thread-locking compounds. Note 3: The terminal extraction tool (PS-SAJ-3/REMD CL902-2117-5) is available separately. ●Low current 10.5 (For4.6 mm dia. hole) 9.5 9.9 B A Ø5.1 1-Ø2 (Conductor insertion verification hole) (6.5) (1) 13 25.6 (38.6) Part number PS-SAC-3Q2 PS-SAC-3N2 CL No. CL236-1008-4 CL236-1015-0 A Ø4.6 Ø3.5 B Ø7 Ø5.5 (Conductor crimp area) Conductor cross section (AWG#) JIS applicable crimp size 6.64~10.52mm (AWG #18) 2 2.63~6.64mm 2 (AWG #10) 8 5.5 Packaging RoHS Bag (10 pieces / bag) YES Note 1: Verify that the conductor remains fully inserted and visible through the 2mm dia. hole after crimping Note 2: The terminal extraction tool (PS-SAC-3/REMD CL902-2118-8) is available separately. Packaging RoHS Bag (100 pieces / bag) YES Note 1: Applicable wire AWG #20 to 24. Note 2: Crimping tool: HT201/PS-PC Note 3: The terminal extraction tool (PS-P(S)AC-1/REMD CL902-2119-0) is available separately. 8 16 A CL No. CL236-1009-7 2 Part number PS-PAC-1D1 2.25 ●Signal The product information in this catalog is for reference only. Please request the Engineering Drawing for the most current and accurate design information. All non-RoHS products have been discontinued, or will be discontinued soon. Please check the products status on the Hirose website RoHS search at www.hirose-connectors.com, or contact your Hirose sales representative. ■Components ●Partitions (insulation) 39 38 18.42 2 6. Ø1 >PBT< 38 18.42 39 PS1-PT1 2 partition shown CL No. Type PS1-PT1 CL236-1016-2 4-partition PS1-PT2 CL236-1017-5 2-partition RoHS YES 1 5 Part number 8 1 Note 1: Used in the 4 contact high current area of the plug or receptacle. Note 2: Sold in quantities of 10 pieces. Ø5.5 2 partition shown ●Dust cover (Plug, high current) Dust cover Ø1 4. 2 >PA< 13 Shown inserted in a signal position PS1-DC2 Part number CL No. RoHS PS1-DC2 CL236-1019-0 YES 3 Note 1: Used in the 4 contact high current area of the plug. Note 2: Sold in quantities of 10 pieces. 2-7 0.8 PS-FS CL236-1010-6 YES Note 1: Used for plugs or receptacles.(Except PS1-2QS) Note 2: Floating distance ± 0.5 mm. M5∞0. 8-2 1.8 1.2 RoHS Ø1 0 CL No. Ø7.75 Part number .7 ●Floating Screw 7.35 6.65 4 (18) 9 The product information in this catalog is for reference only. Please request the Engineering Drawing for the most current and accurate design information. All non-RoHS products have been discontinued, or will be discontinued soon. Please check the products status on the Hirose website RoHS search at www.hirose-connectors.com, or contact your Hirose sales representative. ■Houging/Contacts Combinations ●Plugs Partitions Male contacts -high current PS1-PT1,PS1-PT2 PS-PAJ-3U1,PS-PBJ-3U1 Plug houging PS1-4U32D/6QP PS1-DC2 Dust cover PS1-DC2 Signal contacts PS-SAC-1D1 PS-PBC-3Q1,PS-PBC-3N1 PS-PAC-3Q1,PS-PAC-3N1 Floating screw(Note 1) PS-FS Plug houging PS1-2QP Male contacts -low current Floating screw(Note 2) PS-PAC-3Q1,PS-PAC-3N1 PS-FS ●Receptacles Receptacle houging PS1-4U32D/6QS Female contacts -high corrent Partitions PS-SAJ-3U2 PS1-PT1,PS1-PT2 Signal contacts PS-PAC-1D1 Female contacts-low corrent PS-SAC-3Q2,PS-SAC-3N2 Floating screw(Note 1) PS-FS Receptacle houging PS1-2QS Female contacts-low corrent PS-SAC-3Q2,PS-SAC-3N2 Commercially available screw Note 1: Use the floating screw (PS-FS) whem using PS1-4U3U32D/6QP or PS1-4U33D/6QS, or PS1-2QP houging. Note 2: Use commercially available screw for PS1-2QS housing. 10