Bench Talk

Image Source: Mouser Electronics

By Stuart Cording for Mouser Electronics

By 2033, EU legislators want to see the number of data centres located in the European Union triple.^[1] The motivation for this is reducing the bloc’s dependency on U.S. cloud service providers while ensuring that European businesses have access to digital services that respect the bloc’s data privacy rules. However, there are a few sticking points.

Data centres, like any physical infrastructure, take time to build, with companies like Amazon Web Services (AWS) requiring around two years for such a project.^[2] But what takes much longer is getting grid power to the site. In the U.S., the application process for grid connection can take anywhere from 1 to 3 years. By contrast, the same process currently takes up to seven years in Europe. Connectivity can help speed up installation time, helping data centres and their energy infrastructure get online faster.

Attaching Flexibly to the Grid

Traditionally, such equipment is hardwired, using cable glands or cast resin to achieve the required environmental robustness. When the need for modification arises, both labour and delays caused by hardwiring result in substantial time and money costs.

Thanks to a growing range of connector options, OEMs, their partners, and customers are moving away from the hardwired approach (Figure 1). Not only do connectors simplify and speed up installation, but they also reduce the risk of mistakes. Upfront costs are obviously a key factor when considering a change of approach, but in some situations, using connectors proves more cost-effective than alternatives, even when the equipment is installed without a hitch and is never touched again. But it is the first disconnect where the real savings are found, sometimes as much as 50% over exchanging, modifying, or moving hardwired equipment.

Figure 1: A small local data centre in the Netherlands with on-site solar power generation. (Source: Martijn/stock.adobe.com)

Connectors for High Voltages and Extremely High Currents

By understanding these different market demands, connector solutions have evolved to meet engineers and installers where they are needed most. HARTING’s Han^® HPTC High Performance Transformer Connector Series offers reliability for extremely high-current, high-voltage transformer interfaces (Figure 2). The series is specified for use at voltages from 1,800V to 3,600V AC/DC, with a current-carrying capacity of 400A to 1,400A, and conductor cross-section profiles of 95mm² to 240mm². With its straight metallic housing and angled plug design, the cover and underside connect over the entire contact surface, providing 360° shielding. Installation is also simplified, relying on crimping, after which the contact is simply inserted into the housing and closed, leaving it ready to use on the cable side without recourse to shrinking or taping.

Figure 2: Designed for use at up to 3,600V AC/DC and 1,400A, the Han HPTC Series is designed for use in high voltage transformer interfaces. (Source: HARTING)

To avoid the need for a large inventory of parts, the Han HTPC Series supports numerous coding options. Sixteen different combinations are possible, meaning only a single connector type is required for your transformer connections, helping to keep inventory costs under tighter control (Figure 3). Ingress protection ratings include IP66, IP68, and IP69, while the corrosion-resistant, aluminium die-cast housing ensures long life and reliability, even under shock and vibration.

Figure 3: A single connector with 16 coding options simplifies part inventory. (Source: HARTING)

The Han HPR Single-Pole Connector is ideal for control and monitoring systems that are critical for the energy infrastructure on the grid. Its rugged exterior is designed for a wide range of outdoor environments, making it ideal for connections from infrastructure like switchgear controls to data centre infrastructure, or inverter and controls on solar farms. For connections within wind turbines, energy storage systems, and other power distribution applications, the HARTING Han HPR Single-Pole Connectors provide the ability to quickly disconnect power systems handling large cables carrying current up to 800A and operating at up to 4,000V (Figure 4). These powder-coated connectors also have a railway pedigree, guaranteeing reliability in high-shock, high-vibration environments and protection against ingress through a recessed O-ring (IP68/69k). Outdoor-rated and UV- and corrosion-resistant, a keying system protects against incorrect installation with 36 possible combinations.

Figure 4: Originally designed for the rigours of railways, the Han HPR Single-Pole Connector allows fast disconnect of large current, high voltage cables in any application. (Source: Mouser Electronics)

Changing Requirements for Data Centres

Rapid growth in AI compute has further exposed the cracks in the power architecture of data centres. Even low-level changes in power consumption, such as those caused by the rapid switching between matrix compute and data exchange, are causing issues at the power grid level.^[3] As a result, companies like Nvidia and organisations such as the Open Compute Project (OCP) are exploring 800VDC at the rack,^[4] replacing the 48 VDC standard used today. This should provide seamless delivery of 600kW today and 1MW and beyond in the future.

Data centres are looking to move away from their existing approach—415VAC or 480VAC entering the facility, converting to 48VDC and then 12VDC—by delivering 800VDC directly to the compute rack and performing a 64:1 conversion to 12VDC next to the GPU (Graphics Processing Unit).

Modular connectors can support this change in power architecture, allowing rapid integration of racks with a single error-proof power and data network connector. Construction of the desired connectivity options is simple thanks to HARTING’s rectangular Han-Eco^® Modular Hoods and Housings. The lightweight polyamide material meets UL94 Class V0 flammability requirements, and the single- or double-locking lever mechanism ensures reliable connection and IP65 protection as defined in DIN EN 60529.

The “click and mate” design supports assembly without screws, and, with hundreds of standard inserts that include power (up to 200A/1,000V), protective earth (PE), RJ45, gigabit data, and POF or glass optical fibre, to name a few, all conceivable combinations can be covered. For demanding outdoor applications, the Han-Modular^® Connector System range is available in powder-coated die-cast aluminum (Figure 5).

Figure 5: These Han-Eco and Han-Modular rectangular connectors allow configuration of power, data, and signals that match your application. (Source: Mouser Electronics)

Connectors Offer Flexibility and Cost Savings Over the Hardwired Approach

With a rapidly evolving stand-up infrastructure landscape and a push to significantly expand European data centre capacity, today’s modern connectors offer flexibility that spans from the grid to the server rack. Modular connectors not only carry power but also allow flexible implementation of wired and optical data connections. Robustness is also catered for keeping moisture and dust out, and, with suitable locking mechanisms, guarantees that a surprise power loss cannot occur. Plug-and-play is also supported, so, as with our laptops and PCs, error-free system installation is ensured thanks to pre-tested, pre-configured cable assemblies. And, should something go wrong, it’s easier to troubleshoot, locate the failure point, and either replace or repair.

Author

Stuart Cording is “The Electronics Reporter”—an engineer turned influencer dedicated to helping the electronics community make sense of today’s complex technologies. With 25 years of experience in semiconductors and embedded systems, he uncovers the stories, insights, and practical know-how that help engineers solve real design challenges. Through articles, podcasts, and videos, Stuart connects innovators, shares technical wisdom, and celebrates the people driving progress in deep tech.

Sources

[1] https://commission.europa.eu/topics/competitiveness/ai-continent_en
[2] https://capacityglobal.com/news/aws-warns-european-data-centre-expansion-at-risk-from-seven-year-grid-delays/
[3] https://nvdam.nvidia.com/assets/share/asset/zlg5snufeo
[4] https://www.opencompute.org/blog/realizing-the-open-data-center-ecosystem-vision