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High-Voltage, High-Power and Low-Voltage Systems
Rosenberger high-voltage connector systems were developed especially for power transmission in electric and hybrid vehicles. The harmonized connecting system consists of Rosenberger HV connectors for current loads up to 50 A and 450 A for cable diameters from 2 x 4 mm² to 120 mm² as well as power distribution units for the arrangement of customer-specific assembly formations. Also a generation of 48 V connectors will be available on request.
 
 
HVR®50 Connector System
HVR®50 connectors have been developed in straight and angled variants. The additional slide locking mechanism (CPA – Connector Position Assurance) prevents the connection from unmating accidentally. Despite their small size, they achieve a current intensity of around 60 A at a temperature of 85 °C. HVR®50 connectors are mainly used in ancillary units; for example in electrical heating systems, air-conditioning units or DC/DC converters, and for charging batteries.
HVR®50
HVR®50
HVR®50
Technical Properties
  • Ampacity (6 mm²): 60 A at 85 °C
  • Working voltage 1000 V DC, test voltage 2700 V DC
  • Cross sections 4 - 6 mm²
  • High temperature range from -40 °C to +140 °C
  • IP code mated acc. to IP6K9K / IPX8 / IPXXD
  • IP code unmated acc. to  IPXXD
  • Vibration class II acc. to LV215, PG17

Features and Benefits

  • Minimal dimensions
  • Excellent shielding
  • With HVIL
  • Straight and right angle cable connectors, header

Applications

  • Electrical heater
  • Electrical air condition
  • Battery charger
HVR®200 Connector System
Rosenberger HVR®200 connectors are characterized by their high current carrying capacity of 210 A at 85 °C and their small dimensions. These two-pin connectors can be used as connecting elements between a battery and an inverter and can also be installed in power distribution units. The portfolio includes an angled or straight header as well as a straight cable coupler to suit the relevant installation/usage requirements.
HVR®200
Technical Properties
  • Vibration class II acc. to LV215, PG17
  • IP class mated acc. to IP6K9K / IPXXD / IPX8
  • IP class unmated acc. to IPXXB

Features and Benefits

  • Best dimension-performance ratio
  • With HVIL
  • Cable connectors and header

Applications

  • Battery connection
  • BDU
  • Inverter
HVR®260 Connector System
The 3-pole HVR®260 connector system for collective shield applications is used to connect electric motors up to
a continuous current of 270 A. Despite its lightweight aluminum housing, it also meets extremely high temperature
requirements from -40 °C to +150 °C and achieves vibration severity level IV. Customer-specific variants are avail-
able on request.
HVR®260 Connector System
Technical Properties
  • Ampacity (50 mm²): 270 A at 85 °C
  • Cross sections: 50 - 70 mm²
  • Maximum operation altitude: 5,500 m sealevel
  • Voltage class: HV-2B
  • Mating cycles: ≥ 50
  • Contact resistance: ≤ 0.26 mΩ
  • Working voltage 850 V DC
  • IP class mated acc. to IP 6K9K / IP X8 / IPXXD
  • IP class unmated acc. to IPXXB
  • Temperature range -40 °C to +150 °C
  • Vibration class IV acc. to LV215, PG17

Features and Benefits

  • RoHS: compliant
  • Qualification: according to LV215-2
  • Right angle connector
  • 3–pole connector
  • Costumer specific solutions

Applications

  • E-motor
  • High-voltage connector
HVR®300 Connector System
The new HVR®300 connector system is currently in the development phase and is available on request. It is characterized by a maximum current carrying capacity of 320 A combined with minimal space requirements. The product portfolio includes a 2-pole angled coupler for shielded cables and a cable cross section of 70 mm² along with the corresponding header. A cross section of 50 mm² is available on request. The lever locking mechanism is secured with an additional slider (CPA – Connector Position Assurance) to prevent accidental unmating.
 	 HVR®300 Connector System
Technical Properties
  • Ampacity (70 mm²): 320 A at 85 °C
  • Working voltage 1000 V DC
  • Test voltage 4200 V DC
  • Cross sections 70 mm², 50 mm² on request

Features and Benefits

  • Effective dimension – performance ratio
  • With HVIL
  • Right angle connector, header

Applications

  • High ampacity applications
HVR®420 Connector System
The compact HVR®420 connectors have the highest current carrying capacity in the Rosenberger product port-folio. They achieve a current intensity of 420 A even in the 95 mm² variant. With the largest cable cross section of 120 mm², current intensities of up to 450 A can be achieved at a temperature of 85 °C. The additional slide locking mechanism (CPA – Connector Position Assurance) prevents the connection from unmating accidentally. Typical applications include the supercharging of electric vehicle batteries with up to 450 kWh.
 	 HVR®420 Connector System
Technical Properties
  • Ampacity (120 mm²): 450 A at 85 °C
  • Working voltage 1000 V DC / test voltage 2500 V DC
  • Cross sections  70 - 120 mm² (on request 35 mm²)
  • IPcClass mated acc. to IP6K9K / IPX8
  • IP class unmated acc. to IPXXB
  • Vibration class II according to LV 215 PG17
  • Optional for 120 mm² cable (Al/Cu) and
  • double header in design (test voltage 4300 V DC)

Features and Benefits

  • Highest performance up to 450 A
  • With HVIL
  • Right angle connector, header

Applications

  • Charging and supercharging unit for E-car application
HPK - High-Voltage Power Contacts
The HPK series features 1-pole, 2-pole, or 3-pole connectors which can be used flexibly for copper or aluminum cables in four different cable cross sections. The product portfolio includes straight and angled cable couplers as well as the corresponding headers, either with or without HVIL (high-voltage interlock). The HPK system can achieve 270 A at up to 1000 V. Typical applications in electric vehicles include the connection between battery, inverter, and PDU.
High-Voltage Power Contacts
Technical Properties
  • IP class mated acc. to IP6K9K / IPX8 / IPXXD
  • IP class unmated acc. to IPXX2B

Features and Benefits

  • Highest power with minimum installation space
  • Variability in cable cross section/HVIL/connection
  • Effective EMI shielding
  • Connectivity

Applications

  • Battery connection
  • Inverter
  • E-machine
HV Fuses
HV fuses are fuse systems for PDUs. These fuses are vibration-proof, feature a HVIL (high-voltage interlock), and are characterized by their lightweight plastic housing. The fuse can be replaced together with the corresponding insert without opening the component housing.
HVR® fuse
Technical Properties
  • Range 10 - 40 A
  • Vibration class II acc. to LV215, PG17
  • IP Class mated acc. to IPX4

Features and Benefits

  • Low weight
  • Waterproof
  • Changeable

Applications

  • HV safety
DCS (Direct Contact System) Connection System
The DCS (Direct Contact System) connection system is characterized by a high current carrying capacity combined with minimal space requirements. At 85 °C, the current carrying capacity is 340 A with a cable cross section of 70 mm². A secure connection is achieved with a combination of contact tab and retaining tab by means of a simple plug-in action . Furthermore, this robust connection system offers detachable and non-detachable variants. The connection system can be used for battery charging or for the connection between the battery and the motor components in electric vehicles.
DCS (Direct Contact System) Connection System
Technical Properties
  • Ampacity (70 mm²): 340 A at 85 °C
  • Working voltage 750 V DC
  • Test voltage 4300 V DC
  • Cross sections 35 - 70 mm²
  • IP Class mated acc. to IPX6K9K / IPXXD
  • IP Class unmated acc. to IPXXD
  • Disconnectable version under development
Features and Benefits
  • Minimal installation space
  • Removable or unremovable
Applications
  • Battery connection
  • E-machine
  • Charger
HV Components
In addition to its standard connector portfolio, Rosenberger also develops and manufactures customer-specific high-voltage components. These configurations are adapted to the relevant vehicle architecture in a highly individual manner, whereby various fuses, relays, and other passive and active components can be combined with each other. Low transition resistances are absolutely essential for the internal conductor and shielded cable in order to ensure long-term, low-loss functioning of the electrical components in the vehicle. From the initial idea right through to delivery – Rosenberger uses its component toolkit to develop and manufacture versatile, tailor-made solutions for its customers.
HV Components
Products
  • Power distribution units and Y-splitters (aluminum housing)
  • Busbars
  • Contact systems
  • Insulation material

Properties

  • Insulation
  • EMI shielded
  • LV and HV interfaces
  • AC and DC currents

Applications

  • Cell connection
  • Battery management
LVR®120 Connectors
The LVR®120 connectors come under the class of low-voltage products. Achieving around 120 A at 85 °C and with a cable cross section of 16 mm², they are used for applications such as electrical superchargers and currently achieve vibration severity level 3. The additional slide locking mechanism (CPA – Connector Position Assurance) prevents the connection from unmating accidentally.
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Technical Properties
  • Ampacity (16 mm²): 120 A at 85 °C
  • Working voltage 48 V DC
  • High temperature range from -40 °C to +150 °C
  • Vibration level III acc. to LV215, PG17
  • IP class mated acc. to IP6K9K / IPX8 / IPXXD

Features and Benefits

  • Low weight
  • Small dimensions

Applications

  • Electrical supercharger