High Voltage Circular Connector | Amphe-Lite HV

As electrified systems continue to evolve, engineers need connectors that balance high-voltage capability, secure mechanical engagement, environmental protection, and packaging efficiency. The Amphe-Lite HV high voltage circular connector addresses these requirements through Tri-Start threaded coupling, improved insulation geometry, and IP67 protection when fully mated. Its rugged construction also makes the series a potential solution for other high-voltage DC applications, including industrial electrification and energy storage equipment, subject to application-specific engineering evaluation.

Amphe-Lite HV High Voltage Circular Connector Overview

Amphe-Lite HV is a high-voltage power connector series developed from the established mechanical design principles of the Amphenol Amphe-Lite connector family. While standard Amphe-Lite connectors support a broad range of signal, power, RF, and fiber-optic applications, Amphe-Lite HV incorporates a dedicated high-power contact design and increased insulation considerations for demanding 1000V DC electrical systems.

The series was developed with electric aviation and unmanned aircraft power architectures in mind. These applications require reliable electrical connections between batteries, power distribution units (PDUs), motors, generators, and actuators, often within compact equipment enclosures exposed to vibration, mechanical shock, and temperature variations.

Choosing the right high voltage circular connector is especially important for electrified platforms where electrical performance, connector size, and environmental protection must be considered together.

By combining an aluminum alloy shell, Tri-Start threaded coupling, and high-voltage insulation geometry, Amphe-Lite HV provides engineers with a compact and rugged connection solution for power-intensive applications. The documented connector assemblies provide 120A current capability, 1000V DC operation, and 500 mating cycles.

For additional industry background, the Federal Aviation Administration’s Advanced Air Mobility resources explain emerging aircraft technologies and operating environments associated with eVTOL platforms. Amphe-Lite HV is positioned for electrical interconnect applications within this developing market; final aircraft-level suitability and certification remain subject to applicable equipment and system approval processes.

Amphe-Lite HV at a Glance

• Rated for 120A and 1000V DC high-power electrical applications
• Developed for eVTOL aircraft, drones, and UAV power systems
• Compact, rugged circular connector design with aluminum alloy shell construction
• Tri-Start threaded coupling for secure mechanical engagement
• Enhanced insulation geometry for high-voltage electrical fields
• IP67 ingress protection when properly assembled and fully mated
• Operating temperature range of -55°C to +150°C in documented connector assemblies
• 500 mating cycles
• Crimp and welding contact termination configurations documented
• Normal and A keying options for documented assemblies
• RoHS compliant

Amphe-Lite HV Connector Selection Guide

Selecting the appropriate high voltage circular connector requires evaluating conductor size, termination method, cable outside diameter, and mechanical keying. The Amphe-Lite HV Series offers documented crimp and welding configurations for 120A, 1000V DC power applications.

The following engineering selection matrix compares the documented Size 15 Amphe-Lite HV plug assemblies for eVTOL, UAV, battery distribution, and other suitable high-voltage DC systems.

Engineering Selection Note: The configurations above represent documented Amphe-Lite HV plug assemblies. The selection matrix is not a mating compatibility chart. Connector keying, approved mating interfaces, conductor preparation, and termination procedures must be confirmed against the applicable Amphenol customer drawings.

For assistance selecting the appropriate connector configuration, contact Amphenol Industrial’s market experts.

Key Features & Benefits

120A and 1000V DC Power Capability

The Amphe-Lite HV high voltage circular connector is designed to carry 120A at an operating voltage of 1000V DC. This capability makes the series relevant for high-power electrical pathways within electrified aircraft and other DC power systems. The connector provides a defined electrical interface for applications where current capacity, operating voltage, and mechanical connection integrity must be evaluated together.

Compact Design for eVTOL and UAV Power Systems

In electric aviation and unmanned aircraft applications, packaging efficiency is an important part of the electrical system design. Batteries, power distribution equipment, propulsion components, and control systems must operate within limited installation space. Amphe-Lite HV combines high-power connectivity with a compact circular architecture, helping designers incorporate secure electrical connections into space-constrained equipment.

As a compact high-voltage power connector, Amphe-Lite HV helps engineers address high-current connection requirements while considering mechanical installation and packaging constraints.

Tri-Start Threaded Coupling

The series incorporates the established Amphe-Lite Tri-Start threaded coupling approach, providing secure mechanical engagement in demanding operating environments. This coupling design is particularly relevant to applications where vibration, repeated equipment movement, and mechanical loading can affect connector reliability.

Enhanced High-Voltage Insulation Design

High-voltage electrical systems require careful consideration of dielectric performance, insulation materials, and spacing between conductive surfaces. Amphe-Lite HV incorporates increased insulation and enhanced geometry to address creepage, clearance, and electric field requirements associated with 1000V DC operation.

The insulation system is an important consideration when specifying a high voltage circular connector for electrical equipment operating in demanding environments.

These design characteristics distinguish the HV configuration from standard Amphe-Lite products. Engineers should evaluate published electrical ratings alongside the complete system insulation design and applicable operating conditions.

Rugged Environmental Protection

Amphe-Lite HV combines aluminum alloy shell construction, environmental sealing, and durable coupling components to support demanding applications. The documented assemblies provide IP67 protection when fully mated, along with a temperature range of -55°C to +150°C and 500 mating cycles.

Environmental protection is particularly important when electrical connectors are exposed to moisture, vibration, temperature variation, or contamination. For background on internationally recognized ingress protection classifications, engineers may consult the International Electrotechnical Commission (IEC), including the IEC 60529 framework.

Flexible Contact Termination and Keying

The supplied Amphe-Lite HV engineering drawings document crimp and welding contact assemblies, as well as normal and A keying configurations. These options help engineers select an appropriate connection arrangement based on conductor requirements, cable construction, and mechanical interface design.

Documented configurations include 25 mm² unshielded cable with crimp termination and 35 mm² unshielded cable with welding termination. Mating combinations, contact installation, and cable assembly requirements should always be confirmed against the applicable Amphenol customer drawings.

Typical Applications

The Amphe-Lite HV Series was developed for high-voltage electrical connections within eVTOL aircraft, drones, and UAVs. Its combination of 120A current capability, 1000V DC operation, secure coupling, and environmental protection makes it relevant to electrical systems where high power must be delivered through a rugged connector interface.

Typical and potential applications include:

• Electric vertical takeoff and landing (eVTOL) aircraft
• Drones and unmanned aerial vehicles (UAVs)
• Electric aircraft battery connections
• Battery-to-power distribution unit (PDU) interfaces
• Electric propulsion and motor power connections
• Generator electrical interfaces
• Electrically powered actuator systems
• High-voltage DC power distribution equipment
• Industrial electrification systems, subject to engineering review
• Battery energy storage equipment, subject to engineering review

Electric Vertical Takeoff and Landing (eVTOL) Aircraft

eVTOL aircraft rely on electrical power architectures that connect onboard energy storage, power distribution equipment, propulsion components, and auxiliary electrical systems. Amphe-Lite HV was developed to support these high-power connection requirements through a compact, rugged connector architecture.

The series can be evaluated for battery-to-PDU connections and other suitable electrical interfaces in eVTOL platforms. The FAA Advanced Air Mobility program provides additional context on electrically powered aircraft and emerging vertical-flight applications.

Drones and Unmanned Aerial Vehicles

Industrial drones and UAVs increasingly rely on electrical architectures that combine onboard batteries, distribution equipment, propulsion motors, and control systems. A compact high voltage circular connector helps provide a defined electrical interface for power transfer while supporting the mechanical and environmental requirements of the platform.

Amphe-Lite HV is positioned for these applications where system voltage, current demand, installation space, and environmental conditions are compatible with the documented connector ratings.

Battery Power Distribution and Electric Propulsion

Reliable power transfer between onboard batteries, distribution units, motors, generators, and actuators is central to electrified equipment design. Amphe-Lite HV provides a high-power circular connection option for these electrical pathways, helping engineers select an interface that supports the required voltage and current within a compact mechanical package.

For battery-to-distribution applications, selecting a high voltage circular connector involves evaluating current capacity, operating voltage, termination requirements, and connector durability.

For related high-current power connector technologies, explore the Amphenol TS1 Series, developed for high-current eMobility applications.

Industrial Electrification and Energy Storage

Beyond its documented eVTOL and UAV markets, Amphe-Lite HV may be evaluated for industrial high-voltage DC equipment and battery-based power systems. Potential applications include suitable battery connections, high-current DC distribution pathways, and electrified industrial machinery.

These additional applications require individual engineering review to determine electrical compatibility, environmental suitability, cable selection, and applicable certification requirements. For alternative connector architectures developed specifically for energy storage systems, explore the Amphenol Floating Mate Connector Series.

Amphe-Lite HV Technical Details

The Amphe-Lite HV high voltage circular connector combines high-current contact technology with mechanical features developed from the Amphe-Lite platform. The documented assemblies are rated for 120A at 1000V DC and incorporate an aluminum alloy shell, silver-plated copper alloy contacts, and an enhanced insulation system.

The engineering drawings identify dielectric withstand performance of 3000V AC with a maximum leakage current of 2mA and an insulation resistance requirement of at least 5000 megohms when tested at 1000V DC and 25°C. These values provide additional technical information for engineers assessing high-voltage electrical interfaces.

Engineers evaluating a high-voltage electrical connection should consider the published dielectric withstand performance, insulation resistance, environmental ratings, and available termination configurations.

For environmental performance, the documented assemblies specify IP67 protection in the mated condition, 500 mating cycles, and operating temperatures from -55°C to +150°C. The product presentation also identifies vibration performance at 5-300Hz and 4.76Grms, together with mechanical shock figures for operational and crash-safety conditions. Qualification requirements must be evaluated against the applicable system design and test documentation.

The supplied customer drawings include Size 15 plug assemblies with 25 mm² crimp and 35 mm² welding configurations. Normal and A keying options are documented. These details support preliminary connector selection, although approved mating components, assembly procedures, and specific part-number configurations must be verified before production use.

Unlike the standard Amphe-Lite commercial 38999 connector family, which supports a broad range of signal and power arrangements, Amphe-Lite HV has distinct electrical insulation and contact characteristics. The published HV ratings must not be assumed to apply to other Amphe-Lite configurations.

Installation Considerations

Correct cable selection, contact termination, assembly, and mating are essential to maintaining the electrical and environmental performance of a high-voltage power connector. Engineers and installers should use the applicable Amphenol customer drawings and approved assembly instructions for the selected Amphe-Lite HV configuration.

Key installation considerations include:

• Confirm the operating voltage, current demand, temperature, and electrical transients of the complete system.
• Select the correct cable conductor size and outside diameter for the documented connector configuration.
• Use the specified contact assembly and appropriate crimp or welding process.
• Verify the correct keying arrangement and approved mating connector combination.
• Inspect contact surfaces, sealing components, and cable preparation before final assembly.
• Follow approved coupling and assembly procedures to ensure complete mechanical engagement.
• Verify that the connector is correctly assembled and fully mated before relying on the IP67 protection rating.
• Evaluate cable strain relief, vibration, shock, and thermal loading within the overall equipment installation.
• De-energize the circuit before mating, unmating, or servicing the connector unless the exact product and procedure are specifically approved for another operating condition.

The 120A current rating and 1000V DC operating voltage must be evaluated alongside conductor construction, ambient temperature, termination quality, system protection, and any required derating. These connector ratings do not independently establish compliance with aircraft-level or industrial equipment certification requirements.

For additional high-speed signal requirements within demanding industrial systems, Amphenol also offers the Amphe-Lite Quadrax connector, designed for ruggedized data transmission applications rather than the dedicated high-voltage power configurations described here.

Resources & Support

Amphenol Industrial Operations provides technical information and application support to help engineers evaluate Amphe-Lite HV for high-voltage power systems. Product selection should consider the complete electrical architecture, conductor requirements, mechanical installation, and operating environment.

Amphenol Industrial can assist engineering teams selecting a high voltage circular connector for eVTOL, UAV, and other suitable high-power DC applications.

The following resources can assist with connector evaluation and application planning:

• Amphe-Lite HV Application Note IAN-119: Product background, design approach, and intended eVTOL power applications. Available through the product’s Application Notes download section when published.
• Amphe-Lite HV Engineering Drawings: Connector assembly details, contact configurations, keying arrangements, and cable termination requirements. Request the applicable released drawings from Amphenol.
• Standard Amphe-Lite Series: Related commercial 38999 connector platform for signal, power, RF, and fiber-optic applications.
• Amphe-Lite Quadrax: Rugged high-speed datalink connection technology.
• TS1 Series: High-current electrical connectivity for eMobility applications.
• Floating Mate Connector Series: High-voltage power and signal interfaces for battery and energy storage systems.
• Meet Our Industrial Market Experts: Contact Amphenol Industrial for product selection, technical assistance, and application-specific support.

For eVTOL industry context and electrical system planning, engineers may also reference the FAA Advanced Air Mobility resources and the International Electrotechnical Commission for relevant electrical and environmental standards information. These external resources are provided for general technical reference and do not indicate product-specific approval or certification.

To discuss an application, request configuration support, or obtain additional technical documentation, contact Amphenol Industrial’s market experts. Customers can also use the Request Quote or Request Sample options available on this product page.

Frequently Asked Questions

What is the Amphe-Lite HV Series?

Amphe-Lite HV is a rugged high voltage circular connector series from Amphenol Industrial Operations designed for 120A and 1000V DC electrical applications. It combines Amphe-Lite mechanical design technology with high-power contacts, enhanced insulation geometry, and environmental sealing for demanding electrified systems.

What is the voltage rating of the Amphe-Lite HV connector?

The documented Amphe-Lite HV connector assemblies are rated for 1000V DC operation. Engineering drawings also specify a dielectric withstand voltage of 3000V AC with a maximum leakage current of 2mA.

What is the current rating of Amphe-Lite HV?

The Amphe-Lite HV Series is rated for 120A in the supplied product documentation. Actual application suitability must be evaluated using the selected conductor, contact termination, operating temperature, and complete electrical system requirements.

Is Amphe-Lite HV designed for eVTOL aircraft?

Yes. Amphe-Lite HV was developed for high-power electrical connections associated with eVTOL aircraft, including battery systems, power distribution units, motors, generators, and actuators. Aircraft-level suitability and qualification depend on the complete installation and applicable certification requirements.

Can Amphe-Lite HV be used in drones and UAVs?

Yes. Drones and unmanned aerial vehicles are identified target applications for Amphe-Lite HV. The connector provides a compact, high-power electrical interface for suitable battery, distribution, and electrically powered equipment connections.

Is Amphe-Lite HV waterproof?

The documented Amphe-Lite HV assemblies provide IP67 ingress protection when correctly assembled and fully mated. This rating applies to the specified mated condition and should not be interpreted as protection when the connector is disconnected.

What is the operating temperature range of Amphe-Lite HV?

The supplied Amphe-Lite HV assembly drawings specify an operating temperature range of -55°C to +150°C. Temperature capability must be considered alongside conductor selection, current loading, and overall system conditions.

What termination options are available for Amphe-Lite HV?

The supplied engineering drawings document 25 mm² crimp plug configurations and 35 mm² welding plug configurations. Engineers should confirm the applicable part numbers, termination procedures, and approved cable requirements before specifying a production assembly.

How many mating cycles does the Amphe-Lite HV connector support?

The documented Amphe-Lite HV assemblies specify a durability rating of 500 mating cycles. Proper handling, assembly, mating, and inspection are important to maintaining connector performance.

Is Amphe-Lite HV interchangeable with standard Amphe-Lite connectors?

Amphe-Lite HV builds on the broader Amphe-Lite mechanical design platform but incorporates distinct high-voltage insulation and power contact features. Interchangeability and electrical rating compatibility must not be assumed. Consult Amphenol for the approved mating combinations associated with the specific connector configuration.

Can Amphe-Lite HV be used in industrial or energy storage applications?

Amphe-Lite HV may be evaluated for suitable industrial electrification, battery power, and energy storage applications where its documented voltage, current, mechanical, and environmental characteristics meet system requirements. These applications require engineering review and verification of applicable equipment and connector certification requirements.

What Amphe-Lite HV connector is available for 25 mm² cable?

The documented 25 mm² crimp plug configurations include part number ZH-805487-01S with normal keying and ZH-805487-01SA with A keying. The associated unshielded cable outside diameter range is 9.4 to 10.0 mm. Engineers should confirm the complete cable and mating requirements against the applicable drawings.

What Amphe-Lite HV connector is available for 35 mm² cable?

The documented 35 mm² welding plug configurations include part number ZH-805245-01S with normal keying and ZH-805245-01SA with A keying. The associated unshielded cable outside diameter range is 10.3 to 11.0 mm. Contact termination and mating compatibility should be reviewed before production selection.

What is the difference between the crimp and welding configurations?

The documented 25 mm² configuration uses a crimp contact assembly, while the 35 mm² configuration uses a welding contact assembly. Both documented plug configurations share the published 120A, 1000V DC electrical ratings, but use different contact and conductor termination arrangements.

For engineers selecting a high voltage circular connector for eVTOL, UAV, battery distribution, or other demanding DC power applications, Amphe-Lite HV offers a compact and rugged 120A, 1000V DC connection platform. Contact Amphenol Industrial Operations to review connector configurations, approved mating interfaces, cable requirements, and technical documentation for your project.