High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters...

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High Voltage Contact and Connector Systems for Electric and Hybrid Vehicles

Transcript of High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters...

Page 1: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

High Voltage Contact and Connector Systems for Electric and Hybrid Vehicles

Page 2: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

Status 2014 I For an up-to-date overview of our sales network please refer to our website: www.rosenberger.com

While the information has been carefully compiled to the best of our knowledge, nothing is intended as representation or warranty on our part and no statement herein shall be construed as recommendation to infringe existing patents.

Germany

Rosenberger Hochfrequenztechnik GmbH & Co. KGHauptstraße 183413 FridolfingGermanyPhone + 49 - 8684 - 18 - [email protected]

Europe

FranceRosenberger Hochfrequenztechnik GmbH & Co. KGRepresentation OfficeActipark17, Rue des Frères Lumière67201 EckbolsheimFrancePhone + 33 - 3 - 90 20 76 03Fax + 33 - 3 - 90 20 76 [email protected]

ItalyRosenberger Hochfrequenztechnik GmbH & Co. KGRepresentation OfficeVia Brodolini, 3120863 Concorezzo - MBItalyPhone + 39 - 039 - 96 30306Fax + 39 - 039 - 59 [email protected]

SwedenRosenberger Sverige ABVallgatan 5B17067 SolnaSwedenPhone + 46 - 8 - 6 36 26 00Fax + 46 - 8 - 6 36 26 [email protected]

United KingdomRosenberger Micro-Coax Ltd.2b Mercury HouseCalleva Park, AldermastonBerkshire RG7 8PNGreat BritainPhone + 44 - 1-18 - 9 81 00 23Fax + 44 - 1-18 - 9 81 61 [email protected]

South America

BrazilRosenberger Domex Telecom Ltda.Cabletech Avenue, 601GuamirimCEP 12295-230BR-Cacapava - São PauloBrazilPhone + 55 - 12 - 3221 8500Fax + 55 - 12 - 3221 [email protected]

ChileRosenberger Sudamérica Ltda.Aldunate 1961,Santiago 836-1195ChilePhone + 56 - 2 - 3 67 11 70Fax + 56 - 2 - 3 67 12 [email protected]

North America

Rosenberger North AmericaRepresentation Office 15900 Michigan Ave, Suite 5Dearborn, MI 48126United States of AmericaPhone +1 - 734 - 673 [email protected]: +1 - 248-259 [email protected]

Asia

China, Asia, AustraliaRosenberger Asia Pacific Electronic Co., Ltd.No. 3, Anxiang Road, Block BTianzhu Airport Industrial ZoneBeijing 101300PR ChinaPhone + 86 - 10 - 80 48 19 95Fax + 86 - 10 - 80 48 24 [email protected]

IndiaRosenberger Electronic Co. (India) PvtLimitedPlot No. 263, Sector 6IMT Manesar, GurgaonHaryana-122050IndiaPhone + 91 - 124 - 477 55 00Fax + 91 - 124 - 477 55 [email protected]

JapanFusoh Shoji Co., Ltd.No. 10 - 2, 2-ChomeNagata-Cho, Chiyoda-KuTokyo 100-0014JapanPhone + 81 - 3 - 35 81 90 56Fax + 81 - 3 - 35 81 57 [email protected]

Korea South, Sales AutomotiveDream Holdings Co. Ltd.977-1, Gosaek-dong, Gwonseon-gu,Suwon-siGyeonggi-doKorea (South) (441-813)Phone + 82 - 31 - 243 - 1767Fax + 82 - 31 - 243 - [email protected]

Sales Automotive

HeadquartersRosenberger Hochfrequenztechnik GmbH & Co. KGHauptstraße 1 | 83413 FridolfingP.O. Box 1260 | 84526 TittmoningGermany Phone + 49 (0)8684 18-0 [email protected] + 49 (0)8684 18-1499 www.rosenberger.com

Page 3: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

1Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

Our Rosenberger Online Catalog contains the current standard product range with specific details, including data sheets, assembly instructions and panel piercings.

catalog.rosenberger.com

Unser Rosenberger Online Catalog enthält das aktuelle Standard-Produkt-spektrum mit Detailinformationen wie Datenblätter, Montageanleitungen und Montagebohrungen.

catalog.rosenberger.de

Contents

Company Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

High Voltage Connectors . . . . . . . . . . . . . . . . . . . . . . . 6

HVR®40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

HVR®200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

HPK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

HVR Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Page 4: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

Rosenberger is one of the worldwide leading suppli-ers for controlled impedance and optical connectivity solutions, system components for mobile communi-cation networks, data centers and test & measure-ment and high voltage contact systems.

A global network of Rosenberger research & develop-ment and production centers provides innovation, op-timized cost structure and outstanding local customer service.

Rosenberger Global Network

Rosenberger ist einer der weltweit führenden Anbie-ter von impedanzkontrollierter und optischer Verbin-dungstechnik, Systemkomponenten für Mobilfunk, Datenzentren und Messtechnik und Hochvolt-Kon-taktsystemen für Fahrzeuge.

Ein globales Netzwerk von Rosenberger-Entwick-lungs- und Fertigungszentren bietet Innovation, opti-mierte Kostenstrukturen und lokalen Kundenservice.

USA

Rosenberger North America f Plano TX f Akron PA f Albuquerque NM f Pennsauken NJ

Rosenberger Site Solutions, LLC. Lake Charles LA

Brazil

Rosenberger Domex Telecom Ltda Caçapava-São Paulo

ChileRosenberger Sudamerica Ltda Santiago

2 Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

Company Profile

Page 5: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

Germany

Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing

Rosenberger OSI GmbH & Co. OHG Augsburg

Rosenberger Messtechnik GmbH Radeberg

Hörl Kunststofftechnik GmbH & Co. KG Laufen

Denmark

Rosenberger Danmark a/s Birkerød

United Kingdom

Rosenberger Micro-Coax Ltd. Aldermaston

China

Rosenberger Asia Pacific Electronic Co. Ltd

f Beijing f Dianshan Hu f Dongguan

India

Rosenberger Electronic Co. India Pvt Limited

f Manesar f Goa

Sweden

Rosenberger Sverige AB Solna

Spain

Rosenberger Telecom, S.A. Alcorcón-Madrid

Hungary

Rosenberger Magyarország Kft. f Jászárokszállás f Taksony

France

Rosenberger France Eckbolsheim

Italy

Rosenberger Italia Concorezzo-MB

3Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

Company Profile

Page 6: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

4 Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

Superior Quality

The quality of our products and services is an essential part of our corporate strategy. Rosenberger’s quality philosophy is not just to optimize components and products, but to continuously improve and optimize all processes to ensure customer satis faction: from product development, planning, purchasing, production, sales, logistics and service to environmental policy – all in all, to offer maxi-mum benefit to our customers all over the world.

Responsibility for quality also means being proactive in protecting our environment and natural resources. We endeavour to avoid or minimize environmental pollution – even beyond the requirements of legal regulations whenever possible.

Ausgezeichnete Qualität

Die hohe Qualität unserer Produkte und Serviceleistungen ist ein grundlegender Bestandteil unserer Unternehmensstrategie. Die Rosenberger-Qualitätsphilosophie beinhaltet nicht nur die Optimierung aller einzelnen Produkte, sondern auch die kontinuierliche und abteilungsübergreifende Verbesserung und Optimierung aller Unternehmensprozesse: von der Produktentwicklung über Planung, Einkauf, Produktion, Vertrieb, Logistik bis hin zur Umweltpolitik – mit dem Ziel, allen unseren Kunden weltweit größtmögliche Kundenzu-friedenheit zu bieten.

Verantwortung für Qualität bedeutet auch umweltbewusstes Handeln und Schutz der natürlichen Ressourcen. Unser Ziel ist es, eine Verschmutzung der Umwelt zu vermeiden, beziehungsweise auf ein Minimum zu beschränken – möglichst deutlich unterhalb der ge-setzlich erlaubten Grenzwerte.

Environmental

Environmentally-conscious actions and protection of natural resources are professed company objectives at Rosenberger. A sustain-able and careful approach to protecting our environment, avoidance of unnecessary consumption and environmentally responsible use of raw materials are primary concerns. Rosenberger has been certified to ISO 14001 since 1998.

Umwelt

Umweltbewusstes Handeln und Schutz der natürlichen Ressourcen sind erklärtes Unternehmensziel von Rosenberger. Der nachhalti-ge und behutsame Umgang mit unserer Umwelt und ein sparsamer und ökologischer Einsatz notwendiger Rohmaterialien stehen im Vordergrund. Rosenberger wurde bereits 1998 nach ISO 14001 zertifiziert.

Connectors and cable assemblies manufactured by Rosenberger correspond to the following European Directives:

Die von Rosenberger gelieferten Steckverbinder und Kabel-Assemblies sind mit folgenden EU-Richtlinien konform:

f 2011/65/EU – Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment (RoHS2) f 2012/19/EU – Waste Electrical and Electronic Equipment (WEEE2) f 2003/11/EG and 2000/53/EC – End of Life Vehicle (ELV) f IEC 61760-1 – max. soldering temperature +260 °C for 10 sec. for PCB connectors

Quality – Environment – Product Compliance

IMDS System

Rosenberger is registered with the IMDS system (Internationales MaterialDatenSystem der Automobilindustrie) since 2001. The prod-ucts are fed systematically into the IMDS system.

Rosenberger ist seit 2001 im IMDS (Internationales MaterialDatenSystem der Auto mobilindustrie) registriert. Die Produkte werden sys-tematisch in das System eingegeben.

www.IMDS.de

Company Profile

Page 7: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

5Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

Product Compliance

Rosenberger monitors and supervises all production, quality and logistic processes with the aim of ensuring compliance with customer requirements.

Our solutions are based on integrated and flexible product compliance and include material and product reliability and safety, recycling, reuse and contractual inspections. Our staff is made aware of the product-compliance problems resulting from environment legislation so as to "live and experience" implementation of them and compliance with them.

Produkt-Compliance

Rosenberger überwacht und kontrolliert die gesamten Produktions-, Qualitäts- und Logistikprozesse mit dem Ziel, die Erfüllung der Kundenanforderungen sicherzustellen.

Unsere Lösungen bauen auf eine integrierte und flexible Produkt-Compliance und beziehen Material- und Produktsicherheit, Recyc-ling, Wiederverwendung sowie Vertragsprüfungen mit ein. Unsere Mitarbeiter sind für die aus der Umweltgesetzgebung resultierende Produkt-Compliance-Problematik sensibilisiert, um deren Umsetzung und Einhaltung zu "leben".

Company Profile

Page 8: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

6 Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

High Voltage Connectors

Rosenberger HV connectors - high voltage connectors – 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 40 A and 250 A for cable diameters from 2 x 2.5 mm² to 50 mm² as well as power-distribution units for the arrangement of customer-specific assembly formations. Main focus in the develop-ment of High Voltage connectors was set on lowest contact resistances with optimized EMI performance characteristics.

Rosenberger is a competent development partner for the integration of connector solutions and customer specific solutions with the highest quality and best performance, still meeting customer price targets.

Engine Other applications, e.g. electric heating, power assisted steering, air conditioning

Onboard-charging system AC/DC converterPower-distribution unit

Power-distribution unit

Battery

High Voltage Connectors

Page 9: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

7Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

Performance f Multiple contact points f Low contact resistance f Low mating force f Different diameters available f Constant force diagramm

Advantages f High ampacity f Low internal heating f Easy assembly f Less space necessary f High tolerance compensation

Spring Leaf Technology

The Rosenberger High Voltage connection and accessory portfo-lio is based on a spring leaf technology.

This spring leaf technology provides multiple contact points to achieve lowest contact resistances in the transition area and a high current performance. With silver plated contact pins and direct contact to press in rings best EMI performance can be achieved even after severe conditions of aging compared to direct contact methods to casted material. Due to the multiple connection points to both sides (inner and outer connection diameters) good vibration levels can be achieved.

Rosenberger offers detailed assembly instructions and values for cable side and unit side (Copper & Aluminium cable vari-ants depending on the connector type). In any case touch proof protection acc.to DIN EN 60529 is ensured for any variant. Water-proofness is ensured acc. to IP Codes IP6K9K, IP68. HVIL (high voltage interlock) systems ensure to achieve best safety condi-tions for the operator.

The spring leaf technology ensures nearly constant forces over a wide range of working deflections. Large mating tolerances and temperature changes can be compensated without significant deviation from it's initial forces.

High Voltage Connectors

Page 10: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

0

50

100

150

200

250

300

350

400

Cur

rent

in A

at 1

05 °C

70-95 mm²350 A

6 mm²40 A

16 -35 mm²150-190 A

50 mm²240 A

2-4 mm²19 A

HVR 40HVR 200

HPK …

8 Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

High Voltage Portfolio

f HVR®40 – high-voltage connectors for applications up to 40 A f HVR®200 – high-voltage connectors for applications up to 200 A f HPK – high power contact for applications up to CE: 240 A f HVR Fuses – exchangeable f Customer Specific Solutions f Direct Contact Connector Systems f Power Distribution Units

High Voltage Connectors

Page 11: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

9Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

Rosenberger Number Code

HV Connectors

High Voltage Connectors

H2 K 1 01- W 2 A 035 B1 -ACoding

Plating

Cable diameter specified in mm

Code cable group

Number of center contacts

Backend type

0 screw version outer and center contact

1 crimped outer and center contact

2 mated outer contact - screwed center contact

5 press-fitted outer contact – crimped center contact

9 special types

W crimped outer contact – welded center contact

Serial number

Configuration

1 straight

2 right angle

Gender

K jack

S plug

Connector Series

H2 HVR®200

H4 HPK

HV HVR®40

H9 special products

Page 12: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

10 Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

Rosenberger Number Code

HVR Fuse

High Voltage Connectors

H1 K 1 01- 2 2 S PC0 B1 -ACoding LF-Ampere rating

A 10 A

B 15 A

C 20 A

D 30 A

E 40 A

Plating

PC PEC (Automotive EV-Fuse)

LF Little Fuse

S fuse

Number of center contacts

Backend type

Serial number

Configuration

1 straight

2 right angle

Gender

K jack

S plug

Connector Series

H1 HV Fuse

Page 13: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

11Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

Rosenberger Number Code

HV Device Socket (header)

High Voltage Connectors

HVL 1 02- 5 B- 002 B1 -ACoding

Plating

Serial number

Cable dimension

0 no cable

A 2.5 mm2

B 4 mm2

C 6 mm2

D 16 mm2

E 25 mm2

F 35 mm2

G 50 mm2

H 70 mm2

J 90 mm2

Backend type

Serial number

Configuration

1 straight

2 right angle

Series

HVL HVR®40 header

H2L HVR®200 header

H4L HPK header

Page 14: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

Copyright © Rosenberger 2013 www.rosenberger.com | 1

HVR40 80%-Kurve; Derating frei in Luft

0

10

20

30

40

50

60

70

0 20 40 60 80 100 120 140 160

Curr

ent [

A]

Temperature [°C]

HVR40 R/A 6mm²

HVR40 Straight 6mm²

Derating Graph HVR®40 acc. to DIN EN 60512-5-2

2 x 6 mm² cable (derating graphs for other cable sizes on request)

Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com12

Interface Dimensions HVR®40

Code HVDimensions in mm

HVR®40

Page 15: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

Electrical data

Insulation resistance ≥ 200 MΩ

Voltage classB60 V DC < U ≤ 1500 V DC25 V AC < U ≤ 1000 V AC

Contact resistance (current) ≤ 1.36 mΩ

Contact resistance (EMV) ≤ 10 mΩ

Ampacity for 6 mm²40 A at 105°Cacc. to DIN EN 60512-5-2

Test voltage 2700 V DC

Working voltage 750 V DC

EMI (shielding effectiveness)70 dB (10 kHz – 5 MHz)65 dB (5 MHz – 500 MHz)

High Voltage Interlock (HVIL) available

Mechanical data

Mating cycles ≥ 50

Engagement force ≤ 100 N

Disengagement force ≥ 50 N

Retention force latch ≥ 500 N

Coding efficiency ≥ 300 N

Cable cross sections 2.5 mm², 4 mm², 6 mm²

Vibration class LV215 PG17-II

IP class (mated) IP6K9K/ IPX8/ IPXXD

IP class (unmated) IPXXB

Touch proof acc. to DIN EN 60529

Environmental data

Temperature range -40 °C to +140 °C

RoHS compliant

Design characteristics

Straight and right angle options on header side

Straight version on jack side only

Color coded caps per cable size

Limitations are possible due to the used cable type.

13Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

Technical Data HVR®40

Code HV

Fields of Application

f On board charger f E-heater f E-compressor

Interface Drawing

f RN_079-01

HVR®40

Page 16: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

14 Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

Coding

HVR®40

Color specification

Colors of the plastic housings are in accordance with the listed RAL colors, minor color differ-ences during manufacturing may occur.

Coding PlugColor/RAL-Nr .

ABlack/9005

BBlack/9005

CBlack/9005

DBlack/9005

Coding Jack

A

B

C

D

Cables

f FHLR2GCB2G 2 x 2,5 mm²; LV 216-2 f FHLR2GCB2G 2 x 4,0 mm²; LV 216-2 f FHLR2GCB2G 2 x 6,0 mm²; LV 216-2

HVR®40

Page 17: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

15Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

Products

HVR®40 Connectors

Rosenberger No. Remarks CableAssembly Instruction

HVK102-12A002B1-Ystraight jack 2-pole waterproofseparate in piece parts acc. to data sheet

2.5 mm² MA_HV0004

HVK102-12A004B1-Ystraight jack 2-pole waterproofseparate in piece parts acc. to data sheet

4 mm² MA_HV0004

HVK102-12A006B1-Ystraight jack 2-pole waterproofseparate in piece parts acc. to data sheet

6 mm² MA_HV0004

HVK201-12A002B1-Yright angle jack 2-pole waterproofon request

2.5 mm² MA_HV0007

HVK201-12A004B1-Yright angle jack 2-pole waterproofseparate in piece parts acc. to data sheet

4 mm² MA_HV0007

HVK201-12A006B1-Yright angle jack 2-pole waterproofseparate in piece parts acc. to data sheet

6 mm² MA_HV0007

170-097-00000 protection cap for jackapplicable for all variants

HVL102-5B-001B1-Yheader, 4 screw holesother cable size versions on request

4 mm² MA_HV0010

170-097-00005protection cap for header applicable for all socket variants

-Y: please fill-in requested coding

HVR®40

Page 18: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

Derating Graph HVR®200 acc. to DIN EN 60512-5-2

Interface Dimensions HVR®200

Code H2Dimensions in mm

HVR200 Kupfer Meterware80%-Kurve; Derating frei in Luft

0

50

100

150

200

250

300

0 20 40 60 80 100 120 140 160 180 200

Cur

rent

[A]

Temperature [°C]

16 mm² Cu

35 mm² Cu

Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com16

HVR®200

Page 19: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

Electrical data

Insulation resistance ≥ 200 MΩ

Voltage class 2

Contact resistance (current) ≤ 0.78 mΩ

Contact resistance (EMV) ≤ 10 mΩ

Ampacity for 35 mm²190 A at 105°Cacc. to DIN EN 60512-5-2

Test voltage 2700 V DC

Working voltage 750 V DC

EMI (shielding effectiveness)< 5 mΩ/m at 2 MHz< 10 mΩ/m at 30 MHz

High Voltage Interlock (HVIL) available, Power pins min 1mm advanced

Mechanical data

Mating cycles ≥ 50

Engagement force torque≤ 4.0 Nm ±0.4 Nm pre engagement force < 75 N

Coding efficiency ≥ 300 N

Cable cross sections 16 mm², 25 mm², 35 mm² (on request)

Cable connection angle 180°

Vibration class LV215 PG17-II

IP class (mated) IP6K9K/ IPX8/ IPXXD

IP class (unmated) IPXXB

Touch proof acc. to DIN EN 60529

Environmental data

Temperature range -40 °C to +140 °C

RoHS compliant

Design characteristics

Straight and right angle options on header side

Straight version on jack side only

Color coded caps per cable size

Limitations are possible due to the used cable type.

Technical Data HVR®200

Code H2

17Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

Fields of Application

f Battery connection f BDU f Inverter

Interface Drawing

f RN_081-01

HVR®200

Page 20: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com18

Coding

HVR®200

Color specification

Colors of the plastic housings are in accordance with the listed RAL colors, minor color differ-ences during manufacturing may occur.

Coding JackColor/RAL-Nr .

ABlack/9005

BWhite/9010

CBlue/5012

ZWaterblue/5021

Coding Plug

A

B

C

Z

Cables

f FHLR2GCB2G 16 mm² / 0.21; LV 216-2 f FHLR2GCB2G 25 mm² / 0.21; LV 216-2 f FHLR2GCB2G 35 mm² / 0.21; LV 216-2

HVR®200

Page 21: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

19Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

Products

HVR®200 Connectors

Rosenberger No. Remarks CableAssembly Instruction

H2K102-W2A016B1-Ystraight jack 2-pole waterproofcode A available, other codes on request

16 mm²MA_HV0019 RN_087-01 RN_087-06

H2K102-W2A025B1-Ystraight jack 2-pole waterproofon request

25 mm²MA_HV0019 RN_087-01 RN_087-06

H2K102-W2A035B1-Ystraight jack 2-pole waterproofcode A available, other codes on request

35 mm²MA_HV0019 RN_087-01 RN_087-06

170-099-00003 protection cap jack for H2K102-W2AxxxB1-A

H2S101-02-000B1-Y straight plug 2-pole waterproof (header)MA_HV0017 MB_448

H2S204-02-000B1-Y right angle plug 2-pole waterproof (header)MA_HV0017 MB_448

-Y: please fill-in requested coding

HVR®200

Page 22: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

Derating Graph HPK acc. to DIN EN 60512-5-2

Interface Dimensions HPK

Code H4Dimensions in mm

0

50

100

150

200

250

300

350

0 20 40 60 80 100 120 140 160 180 200

Curr

ent [

A]

Temperature [°C]

50mm² Cu

35mm² Cu

25mm² Cu

0

50

100

150

200

250

300

350

0 20 40 60 80 100 120 140 160 180 200

Curr

ent [

A]

Temperature [°C]

50mm² Alu

35mm² Alu

Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com20

HPK Copper Cables

HPK Aluminum Cables

HPK

Page 23: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

Electrical data

Insulation resistance ≥ 200 MΩ

Voltage classB60 V DC < U ≤ 1500 V DC25 V AC < U ≤ 1000 V AC

Contact resistance (current) ≤ 0.78 mΩ

Contact resistance (EMV) ≤ 10 mΩ

Ampacity for 6 mm²240 A at 105°Cacc. to DIN EN 60512-5-2

Test voltage 2700 V DC

Working voltage 750 V DC

EMI (shielding effectiveness)70 dB (10 kHz – 5 MHz)65 dB (5 MHz – 500 MHz)

High Voltage Interlock (HVIL) available

Mechanical data

Mating cycles ≥ 50

Engagement force1pin: < 100 N2pin: < 100 N

Cable cross sections copper 16 mm², 25 mm², 35 mm², 50 mm²

Cable cross sections aluminum 35 mm², 50 mm²

Coding efficiency ≥ 300 N

Cable connection angle 180°

Vibration class LV215 PG17-II

IP class (mated) IP6K9K/ IPX8/ IPXXD

IP class (unmated) IPXX2B

Touch proof acc. to DIN EN 60529

Environmental data

Temperature range -40 °C to +140 °C

RoHS compliant

Design characteristics

1-3 (1+2) pole connectors

2 screw mounting

Mounting hole- and coding-system

Locking device on harness-side connector acc. to AK standards (VW)

Limitations are possible due to the used cable type.

Technical Data HPK

Code H4

Fields of Application

f Battery connection f Inverter f E-machine

Interface Drawing

f RN_084-01

21Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

HPK

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Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com22

Coding

HPK

Color specification

Colors of the plastic housings are in accordance with the listed RAL colors, minor color differ-ences during manufacturing may occur.

Coding Coding JackColor/RAL-Nr .

Z ARed/3001

Z BBlack/9005

Z CWaterblue/5021

Cables

Copper

f FHLR2GCB2G 16 mm² / 0.21; LV 216-2 f FHLR2GCB2G 25 mm² / 0.21; LV 216-2 f FHLR2GCB2G 35 mm² / 0.21; LV 216-2 f FHLR2GCB2G 50 mm² / 0.21; LV 216-2

Aluminum

f FHLALR2GCB2G 35 mm²; LV 216-2 f FHLALR2GCB2G 50 mm²; LV 216-2

HPK

Page 25: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

23Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

Coding Coding JackColor/RAL-Nr .

B

BBlack/9005

ARed/3001

C

BBlack/9005

CWaterblue/5021

Coding

HPK

Color specification

Colors of the plastic housings are in accordance with the listed RAL colors, minor color differ-ences during manufacturing may occur.

HPK

Page 26: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com24

Products

HPK Connectors with HVIL

Rosenberger No. Remarks Assembly Instruction

H4K111-W1UxxxB1-ZYstraight jack 1-pole with HVIL

MA_HV0008 RN_087-01 RN_087-04

H4K111-W2UxxxB1-ZYstraight jack 2-pole with HVIL

MA_HV0022 RN_087-01 RN_087-04

H4K109-W1UxxxB1-ZYstraight jack 1-polescrew locking feature with HVIL

MA_HV0008 RN_087-01 RN_087-04

H4K109-W2UxxxB1-ZYstraight jack 2-polescrew locking feature with HVIL

MA_HV0022 RN_087-01 RN_087-04

H4S110-92-H00B-YYheader 2-pole with HVIL

170-101-00000protection cap for jackapplicable for all variants

HVIL: High Voltage Interlock Contactxxx: please fill-in cable size-ZY: please fill-in requested coding-YY: please fill-in requested coding

HPK

Page 27: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

25Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

Products

HVIL: High Voltage Interlock Contactxxx: please fill-in cable size-ZY: please fill-in requested coding-YY: please fill-in requested coding

HPK Connectors without HVIL

Rosenberger No. Remarks Assembly Instruction

H4K112-W1UxxxB1-ZYstraight jack 1-pole without HVIL

MA_HV0008 RN_087-01 RN_087-04

H4K112-W2UxxxB1-ZYstraight jack 2-pole without HVIL

MA_HV0022 RN_087-01 RN_087-04

H4K110-W1UxxxB1-ZYstraight jack 1-polescrew locking feature without HVIL

MA_HV0008 RN_087-01 RN_087-04

H4K110-W2UxxxB1-ZYstraight jack 2-polescrew locking feature without HVIL

MA_HV0022 RN_087-01 RN_087-04

H4S110-92-000B-YYheader 2-pole without HVIL

170-101-00000protection cap for jackapplicable for all variants

HPK

Page 28: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

Electrical data

Insulation resistance ≥ 200 MΩ

Voltage classB60 V DC < U ≤ 1500 V DC25 V AC < U ≤ 1000 V AC

Contact resistance (current) ≤ 1.36 mΩ

Contact resistance (EMV) ≤ 10 mΩ

Ampacity for 6 mm²40 A at 105°Cacc. to DIN EN 60512-5-2

Test voltage 2700 V DC

Working voltage 750 V DC

EMI (shielding effectiveness)70 dB (10 kHz – 5 MHz)65 dB (5 MHz – 500 MHz)

High Voltage Interlock (HVIL) available

Mechanical data

Mating cycles ≥ 50

Engagement force ≤ 100 N

Disengagement force ≥ 50 N

Retention force latch ≥ 500 N

Coding efficiency ≥ 300 N

Cable cross sections 2.5 mm², 4 mm², 6 mm²

Vibration class LV215 PG17-II

IP class (mated) IP6K9K/ IPX8/ IPXXD

IP class (unmated) IPXXB

Touch proof acc. to DIN EN 60529

Environmental data

Temperature range -40 °C to +140 °C

RoHS compliant

Design characteristics

Locking by clamp

HVR fuses can't be removed from fuse-housing

No (special) tools necessary to change the Rosenberger HVR fuse

Limitations are possible due to the used cable type.

Technical Data HVR Fuse

Code H1

Fields of Application

f HV Safety

Interface Drawing

f RN_091-01

Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com26

HVR Fuse

Page 29: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

HVR Fuse

Rosenberger No. Remarks Assembly Instruction

H1S101-92SLF0B1changeable fuse 30 Aother fuses on request

H1K101-12SLF0/91B fuse header MA_HV0021

H1K101-12S040/02B press in ring for header RN_091-03

Little Fuse OHEVxxx.SXC (10 A, 20 A, 30 A, 40 A fuse available)

27Rosenberger Hochfrequenztechnik GmbH & Co. KG, Germany, Phone +49 (0)8684 18-0, [email protected], www.rosenberger.com

Products

HVR Fuse

Page 30: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

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Rosenberger Numbers

170-097-00000. . . . . . . . . . . . . . . . . . . . . . . . . . . 15170-097-00005. . . . . . . . . . . . . . . . . . . . . . . . . . . 15170-099-00003. . . . . . . . . . . . . . . . . . . . . . . . . . . 19170-101-00000. . . . . . . . . . . . . . . . . . . . . . . . 24, 25H1K101-12S040/02B . . . . . . . . . . . . . . . . . . . . . . 27H1K101-12SLF0/91B . . . . . . . . . . . . . . . . . . . . . . 27H1S101-92SLF0B1. . . . . . . . . . . . . . . . . . . . . . . . 27H2K102-W2A016B1-Y . . . . . . . . . . . . . . . . . . . . . 19H2K102-W2A025B1-Y . . . . . . . . . . . . . . . . . . . . . 19H2K102-W2A035B1-Y . . . . . . . . . . . . . . . . . . . . . 19H2S101-02-000B1-Y . . . . . . . . . . . . . . . . . . . . . . 19H2S204-02-000B1-Y . . . . . . . . . . . . . . . . . . . . . . 19H4K109-W1UxxxB1-ZY . . . . . . . . . . . . . . . . . . . . 24H4K109-W2UxxxB1-ZY . . . . . . . . . . . . . . . . . . . . 24H4K110-W1UxxxB1-ZY . . . . . . . . . . . . . . . . . . . . 25H4K110-W2UxxxB1-ZY . . . . . . . . . . . . . . . . . . . . 25H4K111-W1UxxxB1-ZY . . . . . . . . . . . . . . . . . . . . 24H4K111-W2UxxxB1-ZY . . . . . . . . . . . . . . . . . . . . 24H4K112-W1UxxxB1-ZY . . . . . . . . . . . . . . . . . . . . 25H4K112-W2UxxxB1-ZY . . . . . . . . . . . . . . . . . . . . 25H4S110-92-000B-YY . . . . . . . . . . . . . . . . . . . . . . 25H4S110-92-H00B-YY . . . . . . . . . . . . . . . . . . . . . . 24HVK102-12A002B1-Y . . . . . . . . . . . . . . . . . . . . . . 15HVK102-12A004B1-Y . . . . . . . . . . . . . . . . . . . . . . 15HVK102-12A006B1-Y . . . . . . . . . . . . . . . . . . . . . . 15HVK201-12A002B1-Y . . . . . . . . . . . . . . . . . . . . . . 15HVK201-12A004B1-Y . . . . . . . . . . . . . . . . . . . . . . 15HVK201-12A006B1-Y . . . . . . . . . . . . . . . . . . . . . . 15HVL102-5B-001B1-Y . . . . . . . . . . . . . . . . . . . . . . 15

Index

Page 31: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg
Page 32: High Voltage Contact and Connector Systems for Electric · PDF fileGermany Headquarters Rosenberger Hochfrequenztechnik GmbH & Co. KG Fridolfing Rosenberger OSI GmbH & Co. OHG Augsburg

RosenbergerHochfrequenztechnik GmbH & Co. KGHauptstraße 1 | 83413 FridolfingP.O. Box 1260 | 84526 TittmoningGermanyPhone + 49 (0)8684 18-0Fax + 49 (0)8684 [email protected]

Certified by ISO /TS 16949 ∙ DIN EN 9100 ∙ ISO 9001 ∙ ISO 14001

Order No.:Info 251HVCat | pA 2372402000/2014

Rosenberger® is a registered trademark by Rosenberger Hochfrequenztechnik GmbH & Co. KG. RosenbergerHSD® is a registered trademark by Rosenberger Hochfrequenztechnik GmbH & Co. KG. All rights reserved.

© 2014 Rosenberger