Skip to main content

Battery Pack Connections for BESS

Battery energy storage systems (BESS) require compact, robust connectors that support power and signal transmission in space-constrained battery packs exposed to heat and vibration over a long service life. Miniaturized, vibration-tolerant connectors from Molex offer secure locking mechanisms and flexible configurations, helping create safe, efficient and high-performance battery modules.

Designing for Compact, Reliable Battery Pack Connections

Design engineers must efficiently route power and signal lines within compact battery enclosures without compromising efficiency or reliability. Safe, high-performance battery packs require robust connectors that can withstand high temperatures, mechanical shock and constant vibration throughout extended operating lifecycles. The need for field maintenance and upgrades calls for intuitive, modular connectivity solutions that can accelerate work and minimize errors.

Design engineers utilize integrated power-and-signal connectors to reduce component counts and optimize internal layouts within space-constrained battery housings. Vibration-resistant connectors with strong locking features ensure stable electrical connections, even in harsh conditions and during repeated use. Modular interconnect systems designed for rapid installation and tool-free servicing help save time and streamline field upgrades.

Molex offers compact, dual-purpose connectors that combine power and signal in a single interface, helping engineers maximize board space within densely packed battery management and control modules.  These rugged connectors incorporate secure locking mechanisms to prevent accidental disconnection in high-vibration environments. Molex’s modular solutions support easy-to-install, tool-free wiring to simplify system assembly and upgrades.

Battery Pack Connectors for Energy Storage Systems

Signal routing is a challenge in tightly packed BESS units, potentially leading to bulkier systems or mechanical interference. Molex’s ultra-compact connectors feature minimal insertion force, facilitating signal routing in confined battery layouts while protecting mating surfaces from damage during assembly.

  Configuration Pitch  Current (max.) Wire Gauge Circuits
C-Grid and C-Grid III Connectors Wire-to-board, board-to-board 2.54mm 3.0A 36 to 22 AWG 1 to 100
iGrid Connectors Wire-to-board 2.00mm 3.0A 28 to 22 AWG 10 to 40
Nano-Fit Connectors Wire-to-board, wire-to-wire 2.50mm 8.0A 26 to 20 AWG 2 to 16
Micro-One Connectors Wire-to-board 2.00mm 4.0A 28 to 22 AWG 2 to 8
Mini-SPOX Connectors Wire-to-board 2.50mm 4.0A 28 to 22 AWG 2 to 15
DuraClik Connectors Wire-to-board 2.00mm 3.0A 30 to 22 AWG 2 to 15
Mini50 Connectors Wire-to-board 1.80mm 4.0A 26 to 22 AWG 4 to 38
ConnTAK50 Connectors Wire-to-board 1.80mm 6.0A 26 to 22 AWG

2 to 6 circuits (single row), 10 and 22 circuits (dual row)

FFC/FPC Connectors

Molex FFC/FPC connectors support compact, flexible routing in tight battery packs, with multiple sizing options that allow for easy-to-use, reliable connections.

SEE PRODUCTS

Battery Management System (BMS) PCB and Signal Interface Connectors

Managing power and signal connections in tight BMS boards requires space-saving, flexible connectors that support mixed-function layouts. Miniaturized, modular connectors from Molex deliver power and signal transmission in a single interface, facilitating efficient PCB layouts while ensuring reliable connectivity.

  Configuration Pitch  Voltage (max.) Wire Gauge Mounting Type
Sabre Connectors Wire-to-board, wire-to-wire 7.50mm 600V 24 to 14 AWG Through-hole technology (THT)
Micro-Fit Connectors Wire-to-wire 3.00mm 600V 30 to 18 AWG THT
Mini-SPOX Connectors Wire-to-board 2.50mm 250V 28 to 22 AWG THT
KK Connectors Wire-to-board, board-to-board 2.54, 3.96, 5.08mm 250V AC/DC 30 to 18 AWG Surface-mount technology (SMT) or THT
C-Grid and C-Grid III Connectors Wire-to-board, board-to-board 2.54mm 250V 36 to 22 AWG SMT or THT
H-DAC 64 Connectors Wire-to-board, wire-to-wire 2.50mm 500V DC 22 to 18 AWG N/A

Communication and Control Ports for Battery Pack Connections

BESS controllers need compact, vibration-tolerant communication ports that deliver power and signal reliably while fitting into tight PCB layouts. With secure locking mechanisms, rugged and space-saving connectors from Molex provide consistent signal integrity across challenging BESS communication interfaces.

  Configuration Pitch  Current (max.) Wire Gauge Circuits Locking
Micro-Fit Connectors Wire-to-board, board-to-board 3.00mm 10.5A 30 to 18 AWG 2 to 24 Friction lock
Micro-One Connectors Wire-to-board 2.00mm 4.0A 28 to 22 AWG 2 to 8 Positive latch
DuraClik Connectors Wire-to-board 2.00mm 3.0A 30 to 22 AWG 2 to 15 Positive latch
MicroClasp Connectors Wire-to-board 2.00mm 3.0A 28 to 22 AWG 2 to 40 Friction lock (optional latch)
  Configuration Pitch  Current (max.) Data Rate (max.) Circuits Locking
HSAutoLink Interconnect System Wire-to-board 0.80, 1.27mm 1.5A 2.0Gbps 4 to 5 Positive lock
HSAutoLink II Interconnect System Wire-to-board 0.80, 1.27mm 1.5A 13.5Gbps 6, 12, 14, hybrid Positive lock
HSAutoLink C Interconnect System Wire-to-board 0.80mm 1.25A (per terminal) 40Gbps 24 Positive lock

Terminal Blocks and Barrier Strips

Molex terminal blocks and barrier strips incorporate screw-clamp terminations to provide durable connectivity that resists vibration and thermal cycling in demanding BESS applications. These components simplify field wiring in frequently changing setups. While terminal blocks support various power levels used in battery modules, insulating barriers ensure safety in high-voltage, compact assemblies.

SEE PRODUCTS

Power Distribution and High-Voltage Interfaces for Battery Pack Connections

BESS power connectors must deliver dependable, high-current performance while withstanding harsh environmental conditions. Molex power-dense connectors offer secure locking and vibration-tolerant sealing to ensure reliability in demanding power interfaces.

  Configuration Pitch  Current (max.) Voltage (max.) Wire Gauge Circuits
Sabre Connectors Wire-to-board, wire-to-wire 7.50mm 18.0A 600V 24 to 14 AWG 2 to 8
Mega-Fit Connectors Wire-to-board, wire-to-wire 5.70mm 30.0A 600V 16 to 10 AWG 2 to 12
Micro-Lock Plus Connectors Wire-to-board 1.25, 2.00mm 4.7A 250V AC RMS/DC 30 to 22 AWG 2 to 16 (single row), 8 to 42 (dual row)
MX150 Connectors Wire-to-board, wire-to-wire 3.50mm 22.0A 60V 22 to 14 AWG 2 to 20
CMC / CMX Connectors Wire-to-board 2.54mm (CMC); 2.50, 3.70mm (CMX) 21.0A (CMC), 15.0A (CMX) 32V DC 22 to 12 AWG 22 to 154

Busbars

Available in multiple shapes and plating options, Molex’s high-current, low-impedance busbars support efficient power delivery in dense, high-voltage BESS layouts.

SEE PRODUCTS

Sensor and Environmental Interfaces for Battery Pack Connections

BESS sensor and environmental interfaces require dependable, space-saving wiring to transmit accurate signals in confined spaces. Molex ultra-compact connectors combine low insertion force, fully isolated terminals and secure locking to ensure reliable sensor signals.

  Configuration Pitch  Current (max.) Wire Gauge  Circuits
Mega-Fit Connectors Wire-to-board, wire-to-wire 5.70mm 30.0A 16 to 10 AWG 2 to 12
Sabre Connectors Wire-to-board, wire-to-wire 7.50mm 18.0A 24 to 14 AWG 2 to 8
Micro-Lock Plus Connectors Wire-to-board 1.25, 2.00mm 4.7A 30 to 22 AWG 2 to 16 (single row), 8 to 42 (dual row)
MicroClasp Connectors Wire-to-board 2.00mm 3.0A 28 to 22 AWG 2 to 40
PicoBlade Connectors Wire-to-board, wire-to-wire 1.25mm 2.5A 32 to 26 AWG 2 to 15
Mini50 Connectors Wire-to-board, wire-to-wire 1.80mm 4.0A 26 to 22 AWG 4 to 38
MX64 Connectors Wire-to-wire 2.54mm 10.0A 22 to 18 AWG 2 to 8

Charging Input Connections for Battery Pack

Charging interfaces in residential BESS must safely carry high currents in tight spaces while ensuring stable and vibration-resistant connectivity. Molex’s high-power-density connectors are designed with secure locking features and strong retention mechanisms to ensure reliable electrical performance during continuous charging cycles and in demanding BESS environments.

  Configuration Pitch  Current (Max.) Voltage (max.) Wire Gauge Circuits
Mega-Fit Connectors Wire-to-board, wire-to-wire 5.70mm 30.0A 600V 16 to 10 AWG 2 to 12
Sabre Connectors Wire-to-board, wire-to-wire 7.50mm 18.0A 600V 24 to 14 AWG 2 to 8
Micro-Lock Plus Connectors Wire-to-board 1.25, 2.00mm 4.7A 250V AC RMS/DC 30 to 22 AWG 2 to 16 (single row), 8 to 42 (dual row)

Custom Cable Assembly Solutions

Molex’s custom cable assemblies offer versatile solutions for low- to mid-power connectivity across various BESS applications. Sealed, overmolded and space-efficient configurations ensure dependable operation and streamlined integration in tight BESS enclosures.

EXPLORE CUSTOM CABLE ASSEMBLIES