BMW i3 Battery High-Voltage Connector: Bulk Supply – The $42 Part That’s Causing 57% of “Intermittent Power Loss” Cases in Rebuilt i3 Packs (Now Available in OEM-Spec, Tested for 10,000+ Cycles)
“A workshop in Portland spent two days diagnosing a 2019 BMW i3 that kept cutting power during acceleration.
The battery pack? Brand new.
The BMS? Verified.
The cells? Balanced and healthy.
Then they inspected the high-voltage connector—and found microscopic arcing on the contact surfaces from a non-OEM unit with slightly misaligned pins.
Under load, resistance spiked, triggering a safety shutdown.
They replaced it with a CNS-sourced BMW i3 Battery High-Voltage Connector, torqued to spec—and the car ran flawlessly for 3,000 miles.”
If you assemble, install, or service BMW i3 battery systems, you know that high-voltage integrity is non-negotiable.
Yet this critical interface is often treated as a commodity—sourced from uncertified suppliers using:
- Substandard copper alloys with higher resistivity
- Inconsistent plating thickness leading to early oxidation
- Poor mechanical tolerances causing partial engagement
- Missing HVIL (High-Voltage Interlock Loop) continuity
The result? Intermittent faults, thermal hotspots, and worst-case scenarios: arc flash or isolation failure.
CNS BATTERY eliminates this risk. We now offer BMW i3 Battery High-Voltage Connector: Bulk Supply—each unit engineered to exact OEM specifications, tested for electrical, thermal, and mechanical reliability, and validated in real-world i3 installations worldwide.
Our BMW i3 Battery High-Voltage Connector features:
- ⚡ Pure copper contacts with silver-nickel plating: Ensures <0.2mΩ contact resistance—matching BMW’s original spec
- 🔒 Precision-molded housing: Made from UL 94 V-0 flame-retardant PBT, rated for 600V DC / 250A continuous
- 🔄 Integrated HVIL circuit: Fully functional interlock loop that communicates pack status to the vehicle—no bypass tricks
- 📏 Exact pin geometry & latch mechanism: Guarantees full insertion depth and secure lock—preventing vibration-induced disconnection
- 🧪 Cycle-tested to 10,000+ insertions: Far exceeding typical service life
Available for all i3 generations (2014–2021), with separate SKUs for 45/50kWh and 62kWh pack interfaces.
Why the High-Voltage Connector Is Your Last Line of Defense
In the BMW i3’s architecture, the main HV connector isn’t just a plug—it’s a safety-critical junction that:
- Carries up to 250A during regen or hard acceleration
- Must maintain isolation resistance >500Ω/V to prevent leakage
- Triggers immediate shutdown if HVIL signal is interrupted
A marginal connector may pass a multimeter test—but fail catastrophically under real load. That’s why OEM-grade materials and tolerances matter.
“We lost a customer’s trust once due to a ‘ghost fault’ from a cheap connector. Since switching to CNS HV connectors, we’ve had zero electrical comebacks in 18 months.”
— Cascade EV Repair, Portland
Built for Professionals Who Demand Zero Compromise
- Bulk pricing: Save up to 35% on orders of 50+ units
- Batch traceability: Each lot includes material certs and contact resistance logs
- Pre-lubricated & sealed: Ships with dielectric grease applied and protective caps—ready for immediate use
- Global compliance: Meets IEC 60512, LV214, and BMW GS 97033-2 standards
Ideal for battery rebuilders, fleet maintenance centers, and EV conversion shops who refuse to gamble on high-voltage connections.
Frequently Asked Questions: BMW i3 Battery High-Voltage Connector – Bulk Supply
Q: Are these connectors compatible with OEM and aftermarket packs?
A: Yes—they’re designed to mate perfectly with both factory and CNS-built i3 battery terminals.
Q: Do I need special tools to install?
A: Only a torque wrench (8.5 Nm) and standard HV safety gear. We include installation torque specs with every order.
Q: What’s the voltage and current rating?
A: 600V DC max, 250A continuous, 400A peak (30 sec)—exceeding i3 operational demands.
Q: Is the HVIL circuit functional out of the box?
A: Absolutely—fully wired and tested. No jumpers or modifications needed.
Q: Can I get them pre-crimped to cable?
A: Currently sold as connector-only units (to match your wiring specs). Custom harness builds available for large-volume partners.
In High-Voltage EV Systems, Trust Isn’t Built on Wires—It’s Built on Connections
And with CNS, every connection is engineered to hold—under pressure, over time, without compromise.
Stop Risking Arc Faults and Phantom Errors—Stock Your Workshop with OEM-Spec BMW i3 High-Voltage Connectors, Validated for Safety, Performance, and Long-Term Reliability. Order in Bulk and Ensure Every Pack You Install Powers On—And Stays On.
Because when lives and reputations are on the line, there’s no room for “close enough.”
Secure Your Bulk Allocation Today—Specify i3 Model Year and Quantity, and Receive Factory-Quality HV Connectors Ready for Safe, Code-Free Installation:
👉 https://cnsbattery.com/ev-battery-home/ev-battery-contact/