Connectors & Adaptors

Rosenberger HV fuses ensure the safety of high voltage PDUs used in electric vehicles. Watertight and vibration-proof, 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.

Rosenberger’s High-Voltage Test & Measurement Solutions deliver deep insights into the EMC behaviors of high-voltage Automotive Traction Networks. Using our powerful HV measurement coupler, dedicated calibration software and calibration kits, EMC experts can perform RF voltage and current reliability calculations with absolute precision. HPK Measurement Coupler The newly developed HV Measurement Coupler for HPK series 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. HPK Calibration Kit Although the HPK measurement coupler includes calibration data, an optional HPK calibration kit is also available. Combined with the RCTD software it enables customers to manage their own calibration requirements themselves. A set of all necessary calibration standards is provided and a description for the acquisition of calibration files is included in the RCTD user manual. Rosenberger recommends 12-monthly calibration intervals and offers a recalibration service to HPK coupler customers if required. RCTD Software Rosenberger Calibrated Time Domain Software (RCTD) was developed to enhance EMC-related, automotive high-voltage measurement capabilities. Within the RCTD Software, the time domain data captured by an oscilloscope using the high-voltage coupler is post-processed to calculate high frequency currents and voltages at the given calibration plane within the high-voltage power train. Therefore, calibration data is created and taken into account before measurement occurs. Delivered on a USB-stick in a sturdy wooden box, the RCTD Software includes the functions to create calibration data and post process the measurement data on a PC or directly on LeCroy HDO oscilloscopes for real-time evaluation. The software can be also used for any other directional coupler.

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.

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.

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.

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.

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. Furthermore, the additional slide locking mechanism (CPA – Connector Position Assurance) prevents accidental disconnection. Typical applications include supercharging electric vehicle batteries up to 450 kWh.

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.

The Multi-Power connector for field installation from Rosenberger is unique in terms of user-friendliness. The new assembly concept combines secure and reliable connections with a fast and simple cable assembly. Within shortest time the connector can be assembled on cables with various cross-sections (2x 2.5 mm² to 2x 16 mm²) and jacket diameters (Ø 7 – 21.5 mm). This way, the connector can be flexible used for both low-power and high-power applications (up to 55 A/60 V DC). Regardless the simple assembly process, the connector ensures highest quality for outdoor use, EMI shielding and low contact resistances.