HALVONEX Connectors
High-Current Low Voltage Solutions for harsh environment
HALVONEX connectors deliver high-performance power connectivity in compact, sealed designs tailored for 48V architectures. Bridging the gap between low-voltage/low-power and high-voltage/high-power systems, this portfolio provides robust, scalable solutions that support currents up to 400A in a compact design. Engineered to perform in harsh environments where vibration, heat, and sealing are critical HALVONEX connectors are well-matched to the demands of electric powertrains and auxiliary systems in trucks, buses, off-highway vehicles, Agriculture & Construction, forklift and industrial equipment.
Key Benefits:
HALVONEX Connector Series
High Power in Low Voltage Systems
Supports up to 400A for 48V architecture, enabling reliable power delivery in modern electrified systems.
Wide Wire Compatibility
Accommodates wire sizes from 6 mm² to 95 mm², providing flexibility for varied application needs.
Sealed for Harsh Environments
Rated IP67 and IP69K for resistance to water, dust, and contaminants in industrial and outdoor settings.
Vibration-Ready Performance
Optimized clamping and sealing systems maintain secure connections under continuous vibration.
Enhanced Reliability
HALVONEX Connectors are built to withstand extreme environmental conditions such as high humidity, dust, vibrations, and corrosive elements.
Flexible Configurations
Available in wire-to-wire and wire-to-board layouts, with options for 90° and 180° orientations.
Safe and Intuitive Handling
Color-coded housings and mechanical keying reduce risk of mis-mating during installation.
Durability in Operation
Made with flame-retardant UL 94 V-0 materials and rated for high-cycle use.
Choose the Right HALVONEX Connector for Your Application
The HALVONEX connector series offers sealed, low voltage, high power solutions designed for demanding vehicle and industrial applications. Two key options, HALVONEX Max and HALVONEX Pro, are optimized for different current and wire size needs. Here is how to decide which is best for your design.
| Feature |
HALVONEX Max | HALVONEX Pro |
|---|---|---|
| Current Capacity | Up to 400A @ 80°C |
~78A @ 28V DC |
| Voltage Range | 60V (up to 100V*) | 60V (up to 100V*) |
| Wire Size Range | 50 to 95 mm² | 6 to 10 mm² |
| Positions | 1 and 2 position options | 2 position |
| Terminals | PCON 21 | AMP MCP 9.5 |
| Sealing | IP67 / IP69K with cover | IP67 / IP69K with backshell |
| Locking Mechanism | Lever lock | Slide lock |
| Best For | High power vehicle systems, EV battery, DC/DC converters, high power air compressors | Compact power needs in steering, HVAC, fuse boxes, and auxiliary units |
* up to 100V (need to be verified and approved by user)
When to Use Each Connector
HALVONEX Connector Series
Use HALVONEX Connector Max
Choose HALVONEX Connector Max when your design requires very high current up to 400A, larger wire sizes from 50 to 95 mm², or rugged backbone power distribution in trucks, buses, agricultural, or off-highway vehicles. It is ideal for EV batteries, eFans, chassis power, and high power compressors.
Use HALVONEX Pro
Choose HALVONEX Pro when your design calls for moderate current up to 78A with compact wire sizes from 6 to 10 mm². It is well suited for auxiliary circuits and subsystems such as HVAC, electro-hydraulic power steering, fuse boxes, heaters, chillers, and cabin electronics.
Key Features:
HALVONEX Connector Series
| Feature | Description |
|---|---|
| Voltage Rating |
Up to 100V* |
| Current Capacity | Up to 400A |
| Wire Size Range | 6 mm² to 95 mm² |
| Sealing Level | IP67 and IP69K |
| Operating Temperature | -40°C to +120°C (Max: +180°C for Ultra) |
| Flammability Rating | UL 94 V-0 |
| Housing Materials | PBT – GF20 V0, PA66-GF13 |
| Configurations | Wire-to-wire, wire-to-board |
| Terminal Systems | PCON 21, MCON 12, AMP MCP |
| Positions Available | 1- and 2-position variants |
| Locking Mechanisms | CPA, TPA, Lever & Slide Locking Systems |
| Orientation Options | 90° and 180° |
* up to 100V (need to be verified and approved by user)
Real-world Applications:
HALVONEX Connector Series
Electric Power Steering (EPS) – Reliable high-current connectivity in steering systems for trucks and buses.
EV Battery Systems – Designed for efficient power distribution in 48V battery architectures.
DC/DC Converters – Supports compact, high-current links in power conversion modules.
High Power Air Compressors – Suitable for auxiliary systems demanding sealed, vibration-resistant connectors.
After-Treatment Systems – Used in emission control modules for commercial and industrial vehicles.
eFans – Provides secure electrical links in cooling fan systems where durability is essential.
Heavy-Duty Vehicles – A strong fit for agriculture, construction, and industrial forklift applications.
Hydraulic Control Units – Maintains stable power supply to hydraulic actuators in braking and suspension systems.
HVAC Systems – Powers heating, ventilation, and air conditioning modules with dependable, sealed connections.
Frequently Asked Questions - FAQ
HALVONEX Max connector
Q: Where are HALVONEX Max connectors typically used?
A: These connectors are well-suited for trucks, buses, construction and agricultural machinery, off-highway equipment, mining systems, and emergency vehicles.
Q: What is the operating temperature range for HALVONEX Max Connector?
A: HALVONEX Max connectors operate reliably from -40°C to +120°C, making them suitable for harsh environments.
Q: Are HALVONEX Max connectors sealed against dust and moisture?
A: Yes. They meet IP67 standards and achieve IP69K protection when used with a backshell.
Q: How many mating cycles are HALVONEX Max connectors rated for?
A: With silver-plated terminals, they are rated for up to 50 mating cycles. Refer to individual part specifications for full details.
Q: What are the standout features of HALVONEX Max connectors?
A: Key features include support for 400A current with 50–95 mm² wire, robust lever locking, multiple mounting options (in-line, flange, sealed flange, PCB), and a sealed thermoplastic rectangular housing.
Frequently Asked Questions - FAQ
HALVONEX Pro connector
Q: What types of vehicles or equipment use HALVONEX Pro connectors?
A: HALVONEX Pro connectors are suited for use in trucks, buses, off-highway and construction vehicles, agricultural equipment, mining and forestry machinery, as well as recreational and marine applications.
Q: What temperature range can HALVONEX Pro connectors withstand?
A: These connectors are rated for operation from -30°C to +100°C, suitable for a wide range of demanding environments.
Q: Are HALVONEX Pro connectors water resistant?
A: Yes. They meet IP67 protection standards and can achieve IP69K rating when used with a backshell.
Q: What is the mating cycle durability of HALVONEX Pro connectors?
A: They support up to 10 cycles with tin-plated contacts and up to 50 cycles with silver-plated terminals. Always check individual product specs for exact values.
Q: What are the key features of HALVONEX Pro connectors?
A: Features include support for 78A with 10 mm² wire, slide-lock mating, in-line or PCB mounting, and a sealed thermoplastic housing for vibration resistance and environmental protection.
