EV02 40-contact battery-swap connector with floating mount

EV02 Battery-Swap Connectors, 250 A, Floating Mount

Battery swap · 250 A · ±5 mm float · 10,000 cycles

EV02 connectors link swappable battery packs to the vehicle. The 40-contact version carries 2 × 250 A power contacts, a ground contact and 37 × 40 A contacts; the 13-contact version 5 power and 8 control contacts. A floating mount with rubber flexure absorbs ±5 mm misalignment in X, Y and Z, guides allow blind mating, and the contacts are rated for 10,000 cycles.

Current rating
250 A or 80 A power; 40 A; 10 A control
Contacts
13 or 40
Float
±5 mm (40-contact)
Protection
IP65 (mated)
Mating cycles
≥ 10,000

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Key features

  • Built for automated battery swapping
  • Floating mount absorbs ±5 mm misalignment (X, Y, Z) and twist
  • Guided blind mating
  • Wire-spring and crown-spring contacts with many contact points
  • Arc-resistant, touch-safe and waterproof design
  • 40 contacts: 2 × 250 A, ground, 37 × 40 A; 13 contacts: 5 × 80 A power, 8 × 10 A control

Specifications

Electrical
ParameterValueCondition
Rated current, 40-contact250 A (Ø 12), 125 A (Ø 6), 40 A (Ø 3)
Rated current, 13-contact80 A power, 10 A control
Withstanding voltage4000 VAC / 1500 VACPower / control
Insulation resistance≥ 5000 MΩ
Contact resistance≤ 0.25 mΩØ 12 mm
Mechanical and environmental
ParameterValueCondition
Durability≥ 10,000 mating cycles
Float±5 mm X, Y, Z40-contact
Vibration50 and 200 Hz fixed; 55–500 Hz sweep, 147 m/s²Interruption ≤ 1 μs
Shock30 g, 11 ms
Operating temperature−55 to +125 °C
ProtectionIP65Mated
FlammabilityUL94 V-0

Parameters not listed above — for example vibration level, leak rate or other environmental tests — can be tested to your requirements, including third-party testing.

Typical applications

  • Electric and hybrid vehicle high-voltage systems
  • Battery packs and energy storage
  • Motor controllers and inverters
  • Electric buses, trucks and special vehicles

Frequently asked questions

Why does a battery-swap connector need to float?

The pack is placed by a robot or lift with some positional error. The floating mount lets the connector align itself during mating without stressing contacts or the pack.

Related series

From sample to production

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  2. Configuration and quote

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  3. Samples

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  4. Your approval

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  5. Series production

    Production follows the approved sample configuration, with machining, molding, plating and assembly in our own Shenyang factory.

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