BarKlip® Busbar Connectors for OCP ORv3

Blind-mate 48 V rack power, from a 150 A IT gear input to 1250 A per contact at the power shelf — silver-plated, float-mounted and fully compliant with ORv3 power distribution.

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The BarKlip ORv3 Range

BarKlip® BK1200 HD I/O 1OU

Up to 1250 A Per Contact, 2500 A Total

The top of the range, built for the AI racks that broke the previous power budget. Thirty-eight independent conducting beams and silver plating hold end-of-life resistance to 0.04 mΩ, while a braided flex cable keeps the 1OU envelope serviceable.

Current: 700 A still air (30°C rise); 1250 A at 45°C rise over 60°C with 300 LFM
Total capacity: 2500 A across load and return
Contact resistance: 0.04 mΩ max. end-of-life
Float: ±3.25 mm horizontal and vertical, floating panel mount
Voltage / temperature: 480 VDC, −40°C to +125°C
Part numbers: 10177674-* (GS-12-2013 / GS-20-0915)

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BarKlip® BK1000 HD I/O 1OU

Up to 1000 A Per Contact, 2000 A Total

The same high-density platform as BK1200 one step down the current curve, for power shelves and BBUs that need four figures per contact without the top-end thermal budget. Braided flex cable, silver-plated contacts and secondary chassis grounding are carried over unchanged.

Current: 530 A still air (30°C rise); 1000 A at 60°C rise with 300 LFM
Total capacity: 2000 A across load and return
Contact resistance: 0.04 mΩ max. end-of-life
Float: ±3 mm horizontal and vertical
Voltage / temperature: 480 VDC, −40°C to +125°C
Part numbers: 10180758-* (GS-12-2032 / GS-20-0926)

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BarKlip® BK600 I/O

Up to 700 A Per Contact, 0.05 mΩ

A longer contact design that maximises wipe against the 6 mm ORv3 laminated busbar, with 22 conducting beams and ultrasonically welded 4 AWG cable. TUV certified as well as UL/CSA, and rated to 480 VDC for higher-voltage rack architectures.

Current: 420 A still air (30°C rise, 4 AWG ×12); 700 A at 45°C rise with 300 LFM
Contact resistance: 0.05 mΩ max. end-of-life
Contacts: 22 independent conducting beams, silver plated
Float: ±3 mm horizontal and vertical
Approvals: UL/CSA E66906, TUV 034414 0045
Part numbers: 10164745-* (GS-12-1751 / GS-20-0745)

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OCP 48V BarKlip® BK500 I/O

ORv3 Power Output, OCP Accepted™

Two individual power circuits plus two secondary chassis grounding contacts in a configurable plug-and-play assembly — the workhorse ORv3 power output connector for power shelves, BBUs and server or storage sleds.

Current: 360 A still air (30°C rise, 8 AWG ×12); 520 A at 45°C rise with 300 LFM
Contact resistance: 0.5 mΩ max. end-of-life
Contacts: 18 independent conducting beams, silver plated
Float: ±3 mm each axis, 6.4 mm side-to-side gatherability
Compliance: ORv3 Power Output specifications (IT gear input)
Part numbers: 10156914-* (GS-12-1587 / GS-20-0628)

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OCP 48V BarKlip® BK150 I/O

ORv3 IT Gear Power Input, With Sense Pins

The IT gear end of the ORv3 power path. Twelve conducting beams carry the sled’s input current, while optional sense contacts give the system mate-last, break-first sequencing for controlled power-up and hot service.

Current: 100 A still air (30°C rise); 150 A per contact with airflow
Sense contact: 1.5 A, mate-last / break-first sequencing
Contact resistance: 0.5 mΩ max. end-of-life
Float: ±3 mm horizontal, ±2 mm vertical
Compliance: ORv3 IT Gear Power Input Solution specifications
Part numbers: 10162876-* (GS-12-1717 / GS-20-0725)

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Where BarKlip Sits in an ORv3 Rack

ORv3 moved the rack to a 48 V vertical busbar, and moved the power connection off the bolted lug and onto a blind-mate clip. Power shelves and battery backup units clip onto the busbar and hand power out; server, storage and accelerator sleds clip on to draw it. Nothing is torqued to spec in the field, and nothing needs a technician behind the rack.

Amphenol’s BarKlip® family covers both ends of that path. On the output side, BK500, BK600, BK1000 HD and BK1200 HD I/O cable assemblies carry 500 A to 1250 A per contact between busbar, cable and board. On the IT gear side, BK150 delivers the 150 A input with optional sense contacts for power sequencing. All of them mate to the same 6.00 ± 0.20 mm laminated busbar and share the same float, grounding and plug-and-play configurability.

The result is a rack that can be built, serviced and upgraded by hand: pull a shelf, slide in a replacement, and the power connection re-makes itself with 50 mating cycles of margin.

Why the Rack Clips On Instead of Bolting Up

150 A to 1250 A Per Contact

One connector family covers the whole ORv3 power path: BK150 at the IT gear input, BK500 and BK600 at the shelf output, BK1000 HD and BK1200 HD for AI-density racks at up to 2500 A total.

Blind-Mate With Real Float

Floating panel mount design supports ±3 mm horizontal and vertical float with 6.4 mm side-to-side gatherability, so sleds and shelves land on a 6 mm laminated busbar without alignment fixtures.

Ultra-Low Contact Resistance

Silver-plated high-conductivity copper alloy contacts with up to 38 independent conducting beams hold end-of-life resistance to 0.04 mΩ on the HD parts — less heat, less loss, at every mate.

Grounding Designed In

Secondary chassis grounding contacts rated 32 A each provide supplemental rack grounding for fault protection, with optional sense pins on BK150 for mate-last, break-first sequencing.

Selecting a Power Output BarKlip

Feature	BK500 I/O	BK600 I/O	BK1000 HD I/O	BK1200 HD I/O
Current, still air (30°C rise)	360 A	420 A	530 A	700 A
Current with 300 LFM airflow	520 A (45°C rise)	700 A (45°C rise)	1000 A (60°C rise)	1250 A (45°C rise over 60°C)
Total capacity, load + return	—	—	2000 A	2500 A
Conducting beams	18	22	38	38
End-of-life contact resistance	0.5 mΩ	0.05 mΩ	0.04 mΩ	0.04 mΩ
Operating voltage rating	60 VDC	480 VDC	480 VDC	480 VDC
Float (horizontal / vertical)	±3 mm / ±3 mm	±3 mm / ±3 mm	±3 mm / ±3 mm	±3.25 mm / ±3.25 mm
Operating temperature	−40 to +105°C	−40 to +105°C	−40 to +125°C	−40 to +125°C
Cable	8 AWG ×12, ultrasonic weld	4 AWG ×12, ultrasonic weld	Braided flex	Braided flex
Part number prefix	10156914-*	10164745-*	10180758-*	10177674-*

Common Specifications Across the Family

Power contacts	High conductivity copper alloy, silver plated
Housing and TPA	Thermoplastic, UL 94V-0, halogen-free
Mating busbar thickness	6.00 ± 0.20 mm laminated ORv3 busbar
Mating force	100 N max. (BK150), 120 N max. (BK500 and above)
Un-mating force	20 N min. (BK150), 15 N min. (BK500 and above)
Durability	50 mating cycles
Termination	Ultrasonic weld between wire and contact

Rack architecture	48 V ORv3 power distribution
Ground contacts	64 A total max. for 2 minutes (32 A per contact)
Operating voltage	60 VDC (BK150, BK500); 480 VDC (BK600, BK1000 HD, BK1200 HD)
Operating temperature	−40°C to +105°C; +125°C on the HD series
RoHS	Compliant with EU Directive 2011/65/EU
Approvals	UL/CSA file E66906; TUV 034414 0045 (BK600); UL 94V-0 and EIA 364 on the HD series
Packaging	Carton

Where These Go

AI and ML Training Racks

High-density accelerator racks where a single shelf output can exceed 1000 A. BK1000 HD and BK1200 HD carry the load with 0.04 mΩ end-of-life resistance, so the power path is not where the thermal budget goes.

Power Shelves and PSUs

ORv3 power shelves clip onto the vertical busbar and hand 48 V out to the rack. BK500, BK600 and the HD series provide the output connection, with configurable cable lengths and terminations.

Battery Backup Units

BBU shelves need the same blind-mate discipline as the PSU shelf, plus supplemental grounding for fault protection. The secondary chassis grounding contacts are standard across the range.

Server and Storage Sleds

BK150 takes the 150 A IT gear input at the sled, with optional sense pins for mate-last, break-first sequencing so the load comes up under control after every hot swap.

Frequently Asked Questions

A blind-mate busbar connector: it clips a cable assembly directly onto the 6 mm laminated busbar of an ORv3 rack, so power shelves, BBUs and IT sleds make and break their 48 V connection by sliding in and out rather than by being bolted up.

It follows the direction of power. BK150 is the ORv3 IT gear power input at the sled, rated 100 A still air and 150 A with airflow. BK500 and BK600 are the power output at the shelf, at 360–420 A still air. BK1000 HD and BK1200 HD are the same output role for AI-density racks, at 530 A and 700 A still air and up to 2000 A and 2500 A total.

Only with their test conditions attached. Every rating on this page is quoted against the temperature rise and airflow it was measured at — for example BK1200’s 1250 A figure is at a 45°C rise over a 60°C ambient with 300 LFM. Design against the still-air numbers unless your airflow is characterised.

The floating panel mount supports ±3 mm of horizontal and vertical float on most of the range (±2 mm vertical on BK150, ±3.25 mm on BK1200 HD), with 6.4 mm side-to-side gatherability. That is what makes hands-free shelf insertion practical.

50 mating cycles across the family, with end-of-life contact resistance specified at that point — 0.5 mΩ on BK150 and BK500, 0.05 mΩ on BK600 and 0.04 mΩ on the HD series.

BK150 is fully compliant with the ORv3 IT Gear Power Input Solution specifications and BK500 with the ORv3 Power Output specifications; both carry OCP Accepted™ recognition. BK600, BK1000 HD and BK1200 HD are OCP-compatible designs built to the same ORv3 power distribution architecture.

Yes. These ship as configurable cable assemblies — wire gauge, length, routing and termination are all specified per application, and the HD parts use braided flex cable where space is tight. Send us the rack drawing and current budget and we will come back with a configuration.

Yes. Quadrep represents Amphenol Communications Solutions across the region, supporting ODMs, contract manufacturers and data center integrators in Singapore, Malaysia, Thailand, Vietnam, Indonesia and the Philippines with samples, datasheets, application engineering and volume quotations.

Specifying an ORv3 Rack?

Talk to our engineering team about BarKlip selection, busbar compatibility, custom cable assemblies, samples or full product specifications.