EMOBILITY + BATTERY
Amphenol Electrification Solutions

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AMPHENOL OVERVIEW

Amphenol is the world leader in connectivity
and sensing solutions for electrified mobility.
As the second largest manufacturer in the world, Amphenol has over 125 manufacturing locations worldwide withengineering teams and businesses poised to deliver regionalized support, customization, and manufacturing, while
also offering the steady supply and strategic impact of a global footprint.
In the quick-shifting and rapidly growing world of electric transportation, we see our entrepreneurial spirit andbreadth of custom and standard offerings as differentiators, offering individual components and assemblies fromthe drive train through to the charging station. An intentionally flat organization with a customer-centric approach,Amphenol stays dynamic and responsive to both large and small projects.

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EMOBILITY + BATTERY PRODUCT CATEGORIES
From high-voltage and low-voltage connectors, to flex and rigid busbars, to complex cable assemblies, Amphenol
supports its customers with full system solutions in the electrification revolution.
How to use this document:This is intended as a glimpse into Amphenol’s capabilities and standard catalog. Due to the large number of parts,
configurations, specifications and details, only a small portion of Amphenol’s full portfolio can be presented in thisformat. For additional information and specific product requests, please use the contacts on page 15.
Radsok Technology ���������������������������������������������������������������������������������������������������������������������������� 5
High Voltage/High Current Connectors ���������������������������������������������������������������������������������������������� 6-8
High Voltage Auxiliary Connectors ������������������������������������������������������������������������������������������������������� 948v Hybrid Architecture Connectors ��������������������������������������������������������������������������������������������������� 10
Signal Connections ��������������������������������������������������������������������������������������������������������������������������� 11
Hybrid (Power + Signal/Data) Connections ������������������������������������������������������������������������������������������� 11
EV Charging������������������������������������������������������������������������������������������������������������������������������������� 12
Cable Assemblies ����������������������������������������������������������������������������������������������������������������������������� 13
Cell Connection System��������������������������������������������������������������������������������������������������������������������� 13
Sensors ������������������������������������������������������������������������������������������������������������������������������������������ 14
Automotive R&D and Test Sensors ����������������������������������������������������������������������������������������������������� 15
Busbars ������������������������������������������������������������������������������������������������������������������������������������������ 16
Value-Add Services �������������������������������������������������������������������������������������������������������������������������� 16
Markets Served ������������������������������������������������������������������������������������������������������������������������������� 17

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RADSOK TECHNOLOGY
The core technology for any power connection system is the contact. The ability to ensure repeatable, symmetricand positive mating is critical for electrical and thermal performance of a connector. Amphenol Radsok® is anadvanced series of contacts designed to maximize power delivery while minimizing space requirements. Radsok
contacts feature a twisted grid hyperbolic structure, enabling long, symmetric contact along each lamella.
Radsok R8S is designed specifically for the automotive industry, minimizing the length and diameter required
for a given current while maintaining excellent temperature response. Available in RoHS compliant, berylliumfree material, the contact is produced in a high-speed, precision stamping and bending process from only two
components. Available in sizes up to 14mm, Radsok connectors are configurable and customizable for a varietyof packaging and routing solutions. Amphenol is continuously improving connector solutions, and have a power
solution for every requirement.

Flat Stamped Grid

Twisted, Hyperbolic
Geometry

Socket Contacts

Key Benefits

4mm Radsok® -R8S

Radsok® Enduro• Higher Amperage with Smaller
Envelopes• High Durability• High Current Ratings• Low Mating Force• Ideal for Board to Busbar		
Applications• Snap-in Connection• Temperature and Corrosion 		
Resistance• Self-cleaning Technology• High Cycle Life: Can be Mated andUnmated for 100k Cycles with
Minimal Degradation• Self-cleaning• Field Replaceable• Good for Fast Charging Applications

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HIGH VOLTAGE/HIGH CURRENT CONNECTORS
Amphenol offers a wide variety of ratings, configurations, pole counts and packaging form factors for all manners ofElectric Vehicle. From light off road use to high power off highway vehicle applications, Amphenol has a standard
connector to offer.
Rugged, dependable and field-proven in countless applications, Amphenol connectors hold up to the harshest
environments. For high-volume automotive applications, Amphenol is adept at working with OEMs and Tier One
suppliers to achieve the necessary form factors and specifications.

Heavysok®

Powersok® -2SC

HVC 6-12mm

Available in 8mm and 14mm Radsok
contact sizes, this connector family isa robust choice for DC traction power,transmission, and motor applications.
• HVIL• Shielded• Sealed IP6k9k• USCAR 2&37, LV 215 Compliant

The Powersok -2SC in 14mm and
90° achieves the highest powertransmission with a conductor crosssection of 95mm2.
• New LPA and CPA• 360° shielding• HVIL• Sealed, powerful connector (rated
for IP67 and IP6K9K)• LV 215 tested

A flexible solution for battery, inverterand other power connections, thisRadsok contact system is available
standard and compliant with USCAR
and LV requirements. Available inalternative cable directions including
90°, 120°, 150°, and 180°.
• HVIL• Shielded• Sealed IP6k9k• USCAR 2&37, LV 215 Compliant

HVSLS800

MSD

HVPT

Standard battery and power
distribution connector, offering shortlead times and low cost production.
• HVIL• Shielded• Sealed IP6k9k• USCAR 2&37, LV 215 Compliant

Manual Service Disconnects available
in several form factors, fused andunfused, and various current andvoltage rating combinations. Amphenol
engineers will work with your current
profile to ensure compatibility.

Passthroughs available inmultiple orientations and sealing
combinations, stackable andconfigurable to fit your terminations
and bend requirements.

2-3 Pole | 800V | 200-320A

2 Pole | 1000V | 180A

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2 Pole | 1000V | 365A®

800V-1500V | Up to 630A

• HVIL• Sealed IP6k9k• USCAR 2&37, LV 215 Compliant

1-3 Pole | 1000V | 220A

1-3 Pole | 25-70mm2 cable• 360 Degree Shielding• Sealed IP6k9k

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HIGH VOLTAGE/HIGH CURRENT CONNECTORSHVSL1000

HV - AC Eyelet Connector

PowerLok

Inline and header mount versions
available, this connector family
offers excellent flexibility andstandard part availability.
• HVIL• Shielded• Sealed IP6k9k• USCAR 2&37, LV 215 Compliant

Automotive flange connection offersa robust solution- form factors andpackaging customization is our specialty.
• 360 degree shielding• Sealed IP6k9k• USCAR 2&37, LV 215 Compliant

One of our most popular bus andtruck connectors, PowerLok offersa robust and high-performing
connection for high power
applications.
• HVIL• Shielded• Sealed IP67
• Metal housing

PowerLok G2

RadLok

HVMC 12mm

Updated design for the popularPowerlok connector series, the
new generation features improved
shielding, sealing, and vibration
performance with automotive-stylefeatures such as CPA.
• HVIL• Shielded• Sealed (IP67/IP6k9K)• Metal Housing

A low cost solution while maintaining
high electrical and thermal
performance, RadLok connectors
feature Radsok technology in acompact package.
• Mechanical Latching without Tool
• Quick Connect Replacement for
Bolt-down Lug

High power 12mm Radsok contacts
allow for strong thermal performance,
while the housing provides for arobust, durable connector withexcellent shielding.
• HVIL• Shielded• Sealed IP6k9k• USCAR 2&37, LV 215 Compliant

1-3 Pole | 1000V | 250A

3 Pole | 50mm wire2

1 Pole | 1000V | 70-500A

1-3 Pole | 1500V | 20-500A

1-3 Pole | 1000V | 20-500A

1-3 Pole | 1500V | 350A

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HIGH VOLTAGE/HIGH CURRENT CONNECTORSSurLok Plus

SurLok Plus EMI

HVC 12mm

The SurLok Plus compression lug
is a field installable, high reliable
alternative to common compression
lugs. Now available in options up to
1500V and 500A in a USCAR and LV
compliant package.
• Sealed IP6k9k• CPA• HVILAll the benefits of the SurLok Pluswith the addition of EMI shieldingand HVIL options.
• HVIL• Shielded• Sealed IP67

12mm flat contacts able to maximize
the connection space thanks to rightangle design.
• Shielded• HVIL• Sealed IP6k9k

ePowerePower Lite

HVMC 14mm

Our most rugged and highest power
EV-specific connector, utilized in
extreme conditions where maximum
power delivery is essential.
• HVIL• Shielded• Sealed IP67

A lower power solution with many
features, ePower Lite features Radsok
technology to minimize footprint andmaximize current delivery.
• HVIL• Shielded• Sealed IP67

Amphenol’s highest power battery
connector, this automotive compliant two pole connector mates highpower output with robust, lasting
design.

1 Pole | 1500V | 120-500A

2-3 Pole | 1000V | 200-700A

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1 Pole | 1000V | 150-250A

2-4 Pole | 800V | 70A

1 Pole | 1000V | up to 250A

2 Pole | 1000V | 450A

• HVIL• Shielded• Sealed IP6k9k

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HIGH VOLTAGE AUXILIARY CONNECTORSElectrification requires shifting conventional auxiliary loads from an engine to traction battery power. To
accommodate strict packaging requirements and decreased current needs, Amphenol has a wide variety of single
to six pole connectors with both blade style and circular RADSOK style contacts.

HVC 4way

HVSLW 282/362/633

HVSL 362-6

High voltage auxiliary connection with
innovative packaging solutions.
• HVIL• Shielded• Sealed IP6k9k• USCAR 2&37, LV 215 Compliant

A light-weight, waterproof version of the
HVSL connector with soldered pins for
PCB board.
• HVIL• Shielded• IP67 unmated, IP6k9k mated, IP2XB(Touch-proof)• USCAR 2&37
• Designed for Automation

Low cost circular terminals designed
to consolidate multiple loads into one
connector.
• HVIL• Shielded• Sealed IP6k9k• USCAR 2&37, LV 215 Compliant

HVBI MonoePower Lite

HVC4P

A more robust, low cost solution for
single pole applications.
• HVIL• Shielded• IP6k9k• USCAR 2&37, LV 215 Compliant

An auxiliary power solution with many
features, ePower Lite features Radsok
technology to minimize footprint andmaximize current delivery.
• HVIL• Shielded• Sealed IP67

High voltage & high current module
for small wire gage.
• Shielded• CPA• Sealed IP6k9k

4 Pole | 800V | 75A

2,3 Pole | 1000V | 32-80A

1 Pole | 1000V | 120-250A

2-4 Pole | 800V | 70A

2-6 Pole | 1000V | 40-95A

4 Poles | 1000V | up to 50A

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48V HYBRID ARCHITECTURE CONNECTORS
Amphenol is a key partner in offering solutions for 48V Hybrid System with established products able to supply
power to different sub-systems, including options for sealed and unsealed designs, CPA and TPA. As with all
Amphenol power connectors, Radsok contact technology allows reliable, high performance.

Active Pinlock

48V Interfaces

Radsok contact technology isapplied to 48V systems and is acost-effective, quick connecting
established solution in the market.
• 8mm and 14mm Radsok R8S• From 16 to 95mm2• Push-button for Disassembly

Cost efficient solutions for transmittinghigh currents in automotive 48V
infrastructure also with combined
HV/LV ports.
• Shielded• Sealed IP6K9K• LV214-215

HVSC1P80

8mm Smartsok-1S

A sealed, USCAR and LV compliant
connector, this is a cost effective solution
when EMI is not a strong concern, but
a standard part with important safety
features is needed.
• Sealed IP6k9k• USCAR 2&37, LV 215 Compliant

Radsok R8S features an optimized
power-density and sophisticated highcurrent applications challenging minimal
space environment• 8mm Radsok R8S• Up to 50mm2• CPA

1 pole | <60V | up to 300A

2-5 poles | up to 150A

1 Pole | 1000V | 180A

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48V – 8mm Radsok
inline connection

1 pole | <60V | up to 240A
Radsok contact technology isfeatured as in-line plug to plugconnection as reliable solution for LV
power application.
• 8mm Radsok R8S• CPA• IP6K9K• LV214 Compliance

1 pole | <60V | up to 240A

Visit amphenol.com for more informationSIGNAL CONNECTIONS
Amphenol offers a wide range of signal connectors able to match any customer requirements. Options include multidensity insert arrangements, sealed and touch-proof solutions, EMI protection, circular and rectangular shape, various
installation method and crimp style.

A Series™

HC32 Series

Ecomate Series

Sealed heavy duty, multi-pin plastic andmetal connections include a wide rangeof products serving many applications.
• Up to 47 Pins
• Sealed IP67/IP69K

HC32 Series is a 32 pin sealed andplastic connection.
• 32 Pins• 13A max
• IP68 (1m/48h) and IP6k9k

Circular, sealed multiway metal andplastic connectors able to cover highdensity insert arrangements.
• Bayonett or rapid coupling systems• From 5 to 300A
• IP65 to 69K

HYBRID (POWER + SIGNAL/DATA) CONNECTIONS
Secure transmissions of data, signals and power are crucial in industrial applications. Amphenol consistently accomplishes
these through its modular interconnect systems in versatile interfaces.

X-Lok Series

3-3-3 Single Pair Ethernet

M Series Sensor

Transmission of data & power in alimited space; push-lock installation,
blind-mating with audible feedback.
• Power/Data/Hybrid up to 3+8

Designed in three mechanical matinginterfaces; supports 1000Base-T1(IEEE 802.3 bp)• 3 Mechanical (Screw Thread/Push
Lock/ Push Pull)• 3 Thread Size Options: M5, M8, M12• 3 Prices to Fit Your Needs• Sealed IP68/IP69K

M series is designed for industrial
process measurement and control
according to IEC standard; offers
secure and reliable data and powertransmission performance.
• Range of Products: M5, M8, Guided
M8, M10.5, M12 7/8” and M23• Ideal for Compact Designed where
Environmental Portection an
Stable Connections are Key.

(50A+1.5A)• Sealed IP68/IP69K• Push-Lock mini: Metal 360° 		
Shielded, <33 contacts, up to
10Gbps Transmission• UL1977 and 2238+50e, mini is
EN61373/SAEJ2839 Shock andVibration Approved

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EV CHARGING
Amphenol serves customers charging anything from passenger to fleet electrified vehicles. Our charging gun and inlet offerings
cover the spectrum of standards available in the market, from CCS (SAE J1772, IEC 62196, EN 17186, UL 2251, CE ) to MCS(SAE J3271, IEC 61851). Liquid-cooled options available.

GB/T

CCS1 SAE DCFC

CCS2 IEC DCFC

• AC up to 80A• DC +500A• Combo Inlet Optional

•
•
•
•

•
•
•
•

MCS

AC SAE J1772

AC IEC

•
•
•
•

•
•
•
•

•
•
•
•

Level 1: +350A
Level 2: +1000A
Level 3: 3000A
1250V

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AC up to 80A UL
DC up to 350A UL
HPC DC up to +500A UL
Inlet up to 150mm2 (500A)

AC up to 80A UL
DC up to 350A UL
HPC DC up to +500A UL
Inlet up to 150mm2 (500A)

AC up to 63A (1 or 3 Phases)
DC up to 400A IEC
HPC DC +500A IEC
Inlet up to 150mm2 (500A)

AC up to 63A (1 or 3 Phases)
DC up to 400A IEC
HPC DC +500A IEC
Inlet up to 150mm2 (500A)

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CABLE ASSEMBLIES
Amphenol offers harness solutions based standard or custom requirements, integrating and complementing thewide range of EV/HEV full interconnect systems.

Expertise in simple and complex cable
assembly and harnessing with large
variety of cable and connector types.
Able to assemble both aluminumand copper wires using Amphenol
branded cable or a supplier of thecustomer’s choosing.

Amphenol has deep knowledge ofevery method of termination, allowing
optimized and repeatable high power
designs. Amphenol specializes inmechanical crimping, ultrasonicwelding, resistance welding, soldering,laser welding and more.

As a value-add service, Amphenol has
cable assembly facility throughout
every major market. These facilities
allow for local production, including
BAA compliance in the US. Several
low-cost options are available basedon delivery location

CELL CONNECTION SYSTEMSCell Connection Systems (CCS) integrate sensors, inter-cell busbars and the associated harnessing structure into thecover of a battery module and pack. The CCS provides temperature and voltage sensing at the cell and busbar level,
and ensures low resistance power connectivity to each cell across the pack.
Amphenol has a long and deep history with both CCS design and manufacturing. With assembly facilities worldwide,
Amphenol offers a local supply chain solution for this vital and complex battery assembly.

CCS - FPC solution
Flexible printed circuits are used toreduce wiring assembly and systemcosts by integrating many elements
in to a single flex design. This single
component replaces individual fuses,
thermistors, voltage sensors andharnessing, among other components.
FPC allows for a very compact,vibration resistant design.

Z-connectors® - FPC/FFC/WTB
Connector
Low profile for blind mating, errorproof and ease of assembly with
audible feedback.
• 8-40 Pin, 0.9,1.8,2.7mm Pitch• 120 VDC and 1A per Pin• LV214 Compliant

Laminated Busbar
A low-profile, safety oriented solution
for intercell connection, Amphenol
has integrated laminated busbar
technology into the battery packsystem. Saving space, cost, andassembly time, this is an effective
solution in multiple applications.

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SENSORS
Amphenol advanced sensing technology provides rapid and precise feedback for component and system level control
requirements. Amphenol carries a large line of sensors for a variety of applications. Thermal monitoring is essential in EV
drivetrain and other applications throughout the vehicle. Inline, probe, ring terminal and clip-on style thermistor products
demonstrate Amphenol’s flexibility with packaging.
Pressure, air quality, and advanced sensors are subject to continuous improvement. Pressure, leak detection, level indication
and rotational position are just a snapshot of Amphenol’s advanced sensing technologies.

Temperature Management
Sensors
Available in multiple packages
for different applications, these
thermistors provide quick response tocoolant temperature in well-sealed or
non-invasive ways.
• Inline, probe, clip-on packages• Sealed connection• Variety of RvT curves and platings

Contact and Non-Contact
Temperature Sensors
Amphenol Advanced Sensors NTC
thermistor provides high reliability,
stability and accuracy for vital battery
temperature feedback.
• 1st in industry infrared-based HVtemp sensing
•
•
•
•

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Multiple terminations available
Configurable RvT curves
Rated up to 210 degrees C
Can sense temperature at a 		distance: charging station 		
cabinets, cables within enclosure...

Position Sensors

Resolver

Rotary and linear position indication
available using Hall Effect andinductive technologies.
• Various outputs, digital and analog• High accuracy and precision• Sealed housings available

High speed inductive position sensor
replaces the resolver in EV motors.
• Greater than 50% weight and 80%
size savings vs. traditional resolver• Low copper content, no magnetic
content• Configurable and scalable• ASIL compliant

Thermal Runaway Detector

Coolant Leak/Water Intrusion
Sensor

A detection solution for slow and fast
thermal runaway is available usingnovel detection methods from provensensors, re-purposed for the demanding
automotive battery industry• Flammable gas sensing for earlycell venting detection• Available for mobile and stationary
applications

Low-profile, cost effective methodof detecting liquid accumulation in abattery pack or other enclosure.
• Fast response to liquid presence• OBD compliant

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AUTOMOTIVE R&D AND TEST SENSORS
Since 1967, PCB Piezotronics has been a premier supplier of precision sensors and instrumentation for major industries. Our
design, engineering, and production teams draw upon state-of-the-art manufacturing capabilities to continually provide
better sensing solutions worldwide.
Product lines including sensors for the measurement of acceleration, acoustics, force, load, pressure, shock, strain, torque,and vibration are backed by our Total Customer Satisfaction guarantee. In a global marketplace driven by innovation andimprovement, PCB® has a sensor for every stage of product development.

Vibration

Acoustics

Auto Safety

PCB Piezotronics manufactures
precision accelerometers to measurevibration, shock, acceleration, andmotion for monitoring, control,and NVH testing applications.
ICP®, piezoelectric, MEMS, andcapacitance sensing technologies
are used to fulfill a wide assortmentof measurement requirements forfield testing, factory production anddesign, as well as in R&D labs toacquire NVH data.

PCB® designs microphones for automotive testing to measure soundpower and sound quality. Our mics
are used for NVH testing, cabin noise
measurements, and noise source
location.

PCB® and Endevco set the industry
standard for crash test accelerometers,
and offer a complete family of
products for auto safety testingneeds. Our legacy undamped 7264C
model is the only accelerometerthat meets the NHTSA standard for
certification tests, with repeatable
results trusted by generations of crashtest engineers. Our new multi-mode
damped accelerometers have little
to no resonance in the frequency
range of interest and offer the highest
sensitivity available for excellent
signal-to-noise ratio. We offer many
package types suitable for on-vehicle
crash testing, including miniature sizes
for hard-to-reach locations.

Force

Pressure
PCB® and Endevco manufacture
miniature pressure transducers withbroad frequency response, perfect for
ABS and airbag testing.

PCB®’s quartz, piezoelectric force andstrain sensors are durable measurement
devices that possess exceptional
characteristics for the measurementof high frequency dynamic force andstrain events. Typical measurements
include dynamic and quasi-static forces
as encountered during actuation,
compression, impact, impulse, reaction,and tension used in fatigue testing
applications.

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15

BUSBARS
Amphenol offers deep experience, modelling capabilities and manufacturing options for all types of busbars.
Recognized experts in simulations concerning current flow, thermal response and induction mitigation, Amphenol
utilizes and provides empirical feedback to leading software firms.
A wide variety of manufacturing facilities complement the modelling capabilities. In Europe, North America andAsia, Amphenol offers extensive manufacturing and engineering capabilities for all ranges of busbar projects.

Power Distribution

Power Conversion

Expert Simulation

Available in multiple layers withvarious powder coating, laminationand other dielectric options. Rigid
and flexible busbars are available incopper or aluminium and can include
a variety of platings and terminations,
including Radsok power contacts.

High frequency and advanced inverters and converters require low
inductance and rigorous thermal andcurrent routing to minimize cost, cooling requirements and size. Amphenol
offers a full engineering and manufacturing service for these busbars

Masters of modelling and simulations,
Amphenol has a long history of engineering high performance busbars.
Thermal, inductive, mechanical andtopology optimization are highlights.

VALUE-ADD SERVICES
Most Amphenol divisions provide additional services to create a total solution and enhance the quality and overall value of the
products delivered. Ranging from simple assembly to more complex system integration, Amphenol works with customers on acase-by-case basis to optimize value for both partners.

Cable Assembly

Junction Box Assembly

Advanced Power Solutions

Amphenol owns appropriate tools fora variety of wire brands to ensure highquality crimps and terminations ofcable assemblies.

When appropriate, such as a significant
portion of the BOM is comprised of Amphenol products, Amphenol offers assembly service on the complete enclosure.

Whether hotel loads or bi-directionalcharging, Amphenol engineers uniquesolutions for electrification throughout
the vehicle

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MARKETS SERVED
Automotive:
Amphenol supports high volume, custom applications as it pertains to passenger and light vehicle markets. Optimized
for geographic proximity, cost and efficiency, Amphenol has manufacturing and engineering centers in every major
market.
Industrial:
Off- and on-highway applications are served for heavier requirements, as well as charging infrastructure for bothpassenger and fleet vehicles. Connector requirements may or may not fall in LV or USCAR bins, but all connectors aretested to high levels of ruggedness. Connectors range from auxiliary level currents up to 1,000 Amps.
Storage:
Grid and local auxiliary storage applications present their own unique set of requirements. Amphenol has a broad arrayof connectors and sensors designed to accommodate this growing market.
Other Lithium Based Applications:
Marine, aviation, space, rail and mass transit all present unique challenges and opportunities for the electrification
space. Amphenol leverages its extensive experience in each of these industries to identify solutions and work withcustomers as needed to remain on the cutting edge.

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CONTACTS
Roxane Debaty
EV & Battery – Americas Business Development Director
Amphenol Automotive, Industrial and Sensors
M: +1 203 213 8658
rdebaty@amphenol.com
Giangiacomo De Ambrosi
EV & Battery - EMEA Business Development Director
Amphenol Automotive, Industrial and Sensors
M: +39 342 1002866
giangiacomo.deambrosi@amphenol.de
Mariano Rigotti
EV Charging - Business Development Director
Amphenol Industrial
M: +1 607 237 1618
mrigotti@amphenol-ecs.com

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NOTES

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www.amphenol.com