Rosenberger Headquarters Germany   Rosenberger locations
deutsch
Home Markets & Products Online Catalog Company News & Events Service Job & Career Contact Distributors Microsites
High-Voltage, High-Power and Low-Voltage Systems
Developed especially for optimized power transmission in electric and hybrid vehicles, the extensive portfolio of Rosenberger high-voltage connector products is designed to meet customer requirements for maximum quality, reliability, performance, and price competiveness. Up to 50 A and 450 A current loads from 2 x 4 mm2 to 120 mm2 cable diameters can be supported, as well as HV components e.g. power distribution units for customer-specific assemblies.
When electrical power transmission performance really counts Rosenberger has the perfect connection.
 
 
 
HVR®50 Connector System
Rosenberger HVR®50 connectors are available in straight and angled variants. The additional slide locking mechanism (CPA – Connector Position Assurance) prevents accidental disconnection. Despite their small size these connectors achieve a current capacity of approximately 60 A at 85 °C. HVR®50 connectors are mainly used in ancillary units such as electrical heating systems, air-conditioning units, DC/DC converters, and for charging batteries.
 
HVR®50
HVR®50
HVR®50
Technical Properties
  • Current capacity (6 mm²): 60 A at 85 °C
  • Working voltage 1000 V DC
  • Test voltage 2700 V DC
  • Temperature range -40 °C to +140 °C
  • IP code mated acc. to IP6K9K / IPX8 / IPXXD
  • IP code unmated acc. to  IPXXB
  • Vibration class acc. to LV215 PG17-II
  • Mating cycles ≥ 50
  • Cross sections 4 mm², 6 mm²

Features and Benefits

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

Applications

  • Electrical heater
  • Electrical air condition
  • Battery charger
  • DC/DC converters

Cables

  • FHLR2G2GCB2G 4 mm² / 0.31 mm / LV216-2
  • FHLR2G2GCB2G 6 mm² / 0.31 mm / LV216-2
  • FHLR2GCB2G 6 mm² / 0.31 / LV216-2
HVR®200 Connector System
Rosenberger HVR®200 connectors offer an excellent dimension/performance ratio, combining high current carrying capacity of 210 A at 85 °C while keeping dimensions to a minimum. These two-pin connectors are ideal for connecting elements between a battery and an inverter, or for installation in power distribution units (PDU). To suit the relevant installation or usage requirements, the portfolio includes an angled or straight header as well as a straight cable coupler.
 
HVR®200
HVR®200
Technical Properties
  • Current capacity (35 mm²): 210 A at 85 °C
  • Working voltage 750 V DC
  • Test voltage 2700 V DC
  • Temperature range -40 °C to +140 °C
  • IP class mated acc. to IP6K9K / IPXXD / IPX8
  • IP class unmated acc. to IPXXB
  • Vibration class acc. to LV215 PG17-II
  • Mating cycles ≥ 50
  • Cross sections 16 mm², 35 mm²

Features and Benefits

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

Applications

  • Battery connection
  • BDU
  • Inverter

Cables

  • FHLR2GCB2G 16 mm² / 0.21 mm
  • FHLR2GCB2G 35 mm² / 0.21 mm
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 is capable of operating safely at extreme temperature ranges from -40 °C to +150 °C. It is certified to vibration severity level IV. Customer-specific variants are available on request.
 
HVR®260 Connector System
HVR®260 Connector System
Technical Properties
  • Current capacity (50 mm²): 270 A at 85 °C
  • Working voltage 850 V DC
  • Voltage class HV-2B
  • Temperature range -40 °C to +150 °C
  • IP class mated acc. to IP 6K9K / IP X8 / IPXXD
  • IP class unmated acc. to IPXXB
  • Vibration class acc. to LV215 PG17-IV
  • Maximum operation altitude: 5.500 m sealevel
  • Contact resistance: ≤ 0.26 mΩ
  • Mating cycles: ≥ 50
  • Cross sections: 50 mm², 70 mm²

Features and Benefits

  • RoHS: compliant
  • Qualification: according to LV214
  • Right angle connector
  • 3–pole connector

Applications

  • E-motor
  • Costumer specific solutions
HVR®300 Connector System
The Rosenberger HVR®300 connector system not only provides a maximum current carrying capacity of 320 A, it takes up minimal space. It features 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
HVR®300 Connector System
Technical Properties
  • Current capacity (70 mm²): 320 A at 85 °C
  • Working voltage 1000 V DC
  • Test voltage 4800 V DC
  • Temperature range -40 °C to +85 °C
  • IP class mated acc. to IP6K9K / IP6K6K /IP6K7
  • Vibration class acc. to LV124-II
  • Mating cycles ≥ 50
  • 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

Cables

  • FHLR2GCB2G / 70 mm² / 0.21 mm
HVR®420 Connector System
Highly compact, HVR®420 connectors offer the highest current carrying capacity in the Rosenberger product portfolio. Even the 95 mm² variant safely enables current transmission of 420 A while up to 450 A can be achieved at 85 °C with the largest cable cross section of 120 mm² on request. Furthermore, the additional slide locking mechanism (CPA – Connector Position Assurance) prevents accidental disconnection. Typical applications include supercharging electric vehicle batteries up to 450 kWh.
 
HVR®420 Connector System
HVR®420 Connector System
Technical Properties
  • Current capacity (120 mm²): 450 A at 85 °C
  • Working voltage 1000 V DC
  • Test voltage 2500 V DC
  • IP class mated acc. to IP6K9K / IPX8
  • IP class unmated acc. to IPXXB
  • Vibration class acc. to LV 215 PG17-II
  • Mating cycles ≥ 50
  • Cross sections  35 mm², 70 mm², 95 mm², (120 mm² on request)
  • 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

Cables

  • FLR2GCB2G / 35 mm² / 0.21 mm / LV216-2
  • FHLR2GCB2G / 70 mm² / 0.21 mm / LV216-2
  • FHLR2GCB2G / 95 mm² / 0.21 mm / LV216-2
  • FHLR2GCB2G / 120 mm² / 0.21 mm / LV216-2 (on request)

 

 

HPK - High-Voltage Power Contacts
The Rosenberger HPK system can achieve 275 A at up to 1000 V. With their excellent vibration and current capacity performance the HPK connectors are well-suited to typical high voltage electric vehicle applications such as the connection between battery, inverter and PDU.
The range includes 1-, 2-, or 3-pole connectors which for maximum flexibility can be used with copper or aluminum cables in four different cable cross sections. Straight and angled cable couplers as well as corresponding headers are available, either with or without HVIL (high-voltage interlock).
 
High-Voltage Power Contacts
High-Voltage Power Contacts
Technical Properties
  • Current capacitiy (50 mm²): 275 A at 85 °C
  • Working voltage 1000 V DC
  • Test voltage 3200 V DC
  • Temperature range -40 °C to +140 °C
  • IP class mated acc. to IP6K9K / IPX8 / IPXXD
  • IP class unmated acc. to IPXXB
  • Vibration class acc. to LV215 PG17-II
  • Mating cycles ≥ 50
  • Cross sections 16 mm², 25 mm², 35 mm², 50 mm²

Features and Benefits

  • Highest power with minimum installation space
  • Versatile product range
  • High temperature and vibration performance
  • Design makes these series easier to assemble, creating faster processes and higher quality
  • With or without HVIL (high-voltage interlock) 

Applications

  • Battery connection
  • Inverter
  • E-machine - PDU

Cables

Copper

  • FHLR2GCB2G 16 mm² / 0.21
  • FHLR2GCB2G 25 mm² / 0.21
  • FHLR2GCB2G 35 mm² / 0.21
  • FHLR2GCB2G 50 mm² / 0.21

Aluminum

  • FHLALR2GCB2G 25 mm²
  • FHLALR2GCB2G 35 mm²
  • FHLALR2GCB2G 50 mm²
HPK Measurement Coupler Kit
Rosenberger's High-Voltage Test & Measurement Solutions deliver deep insights into the EMC behaviors of high-voltage Automotive Traction Networks. Using our powerful HPK Measurement Coupler Kit, dedicated Calibration Software and Calibration Kits, EMC experts can perform RF voltage and current reliability calculations with absolute precision.

HPK Measurement Coupler Kit
The newly developed HPK Measurement Coupler Kit from Rosenberger enables a minimally invasive testing method for measuring the reliability of RF voltages and currents. In conjunction with a dedicated calibration process, patented algorithms accurately calculate the RF currents and voltages in the calibration reference plane.

Furthermore, due to the minimal invasion techniques deployed by the coupler there is no risk of impairment to harness performance when under test. The watertight and robust design also means testing can be carried out under any environmental conditions.

 

DCS (Direct Contact System) Connection System
With its high capacity, compact design, the Rosenberger DCS is perfect for space-confined high voltage applications where direct connection is a prerequisite. With a cable cross-section of just 70 mm² the current carrying capacity is 340 A at 85 °C, making it ideal for battery charging or enabling direct connection between the battery and motor components used in electric vehicles.
The combination of contact and retaining tabs ensures a simple plug-in action is all that's required to achieve a totally secure connection. Furthermore, this robust and versatile connection system also offers detachable and non-detachable variants.
 
DCS (Direct Contact System) Connection System
Technical Properties
  • Current capacity (70 mm²): 340 A at 85 °C
  • Working voltage 1000 V DC
  • Test voltage 4300 V DC
  • Temperatur range -40 °C to +130 °C
  • IP Class mated acc. to IPX6K9K / IPXXD
  • Vibration class acc. to LV215 PG17–II
  • Cross sections 35 mm², 50 mm², 70 mm²
  • Disconnectable version under development

Features and Benefits

  • Allows direct connection between cable and PDU (Power Distribution Units)
  • Minimal installation space
  • Removable or unremovable

Applications

  • Battery connection
  • E-machine
  • Charger

Cables

  • FHLR2GCB2G 35 mm² / 0.21 mm
  • FHLR2GCB2G 50 mm² / 0.20 mm
  • FHLR2GCB2G 70 mm² / 0.20 mm

 

 

HV Fuses
Rosenberger HV fuses ensure the safety of high voltage PDUs used in electric vehicles. Watertight and vibrationproof, they feature a HVIL (High-Voltage Interlock) and are characterized by their lightweight plastic housing. Fuses and the corresponding insert can easily be replaced without opening the component housing.
HVR® fuse
Technical Properties
  • Range 10 - 40 A
  • Working voltage max. 850 V DC
  • Test voltage 2700 V DC
  • Temperatur range -40 °C to +125 °C
  • Vibration class acc. to LV215, PG17-II
  • IP Class mated acc. to IPX4
  • Mating cycles ≥ 25

Features and Benefits

  • Low weight
  • Waterproof
  • Changeable

Applications

  • High-voltage safety for PDUs (Power Distribution Units)
HV Components
Complementing its standard connector portfolio, Rosenberger develops and manufactures customer-specific high-voltage components for electric and hybrid vehicles. These enable the lowest possible transition resistances, ensuring long-term low-loss performance and reliability in critical electrical systems such as those for battery charging, cell management, heating, and air conditioning.
From concept to final delivery, Rosenberger high voltage custom components are the perfect fit every time. Using its component toolkit, including PDUs, Y-splitters, Busbars and Cell Modules, Rosenberger can develop and manufacture a wide array of tailor-made solutions. These are designed and configured precisely to the relevant vehicle architecture, allowing ideal combinations of the various fuses, relays and other passive and active components required.
 
HV Components
Products
  • Power distribution units  (PDU)
  • Y-splitters (aluminum housing)
  • Busbars - cell module connectors
  • Contact systems
  • Insulation material

Properties

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

Applications

  • Cell connection
  • Battery management
LVR®120 Connectors
Compact and lightweight, low-voltage Rosenberger LVR®120 connectors are ideal for such applications as electrical superchargers. Achieving approximately 120 A at 85 °C with a cable cross section of just 16 mm² they are certified to Vibration Severity Level 4. Furthermore, the additional slide locking mechanism (CPA – Connector Position Assurance) prevents accidental unmating.
 
LVR®120 Connectors
Technical Properties
  • Current capacity (16 mm²): 120 A at 85 °C
  • Working voltage 48 V DC
  • Temperature range -40 °C to +150 °C
  • IP class mated acc. to IP6K9K / IPX8 / IPXXD
  • Vibration class acc. to LV215, PG17-IV
  • Mating cycles ≥ 50
  • Cross section 16 mm²

Features and Benefits

  • Low weight
  • Small dimensions

Applications

  • Electrical supercharger