HPCR4T Series High Power Four-Terminal Precision Current Sensing Resistors
Non-inductive copper manganin resistive element sealed in ceramic case with cement moulding
Rated current 35A to 65A depending on resistance value; 70A maximum at 0.5mΩ
Resistance range 0.5mΩ to 4mΩ
Four-terminal (Kelvin) connection eliminating lead and contact resistance from the measurement path
Tolerance options ±0.5%, ±1%, and ±2%
TCR maximum ±30 ppm/°C
Low inductance construction with high pulse power capability
Operating temperature range −25°C to +150°C
Insulation resistance 20 MΩ minimum at DC 500V
Dielectric withstanding voltage AC 1500V for 1 minute
Short-time overload rated at 2.5× power rating for 5 seconds
Excellent long-term stability — ±0.1% resistance shift after stability testing
Through-hole termination — RoHS compliant
What are the HPCR4T Series High Power Four-Terminal Precision Current Sensing Resistors?
The HPCR4T is a high-power through-hole precision shunt resistor built around a non-inductive copper manganin element housed in a ceramic case and sealed with cement moulding. It is designed for current sensing applications demanding both high continuous current capacity and four-terminal Kelvin measurement accuracy in the sub-4 milliohm range. Where the PCR-4T addresses general-purpose precision shunt requirements at up to 3W, the HPCR4T steps up to continuous current ratings of 35A to 65A depending on resistance value — reaching 70A at the lowest 0.5mΩ value — making it suited to the high-current measurement loops found in power converters, traction drives, and industrial power modules where a chip-scale shunt would be inadequate.
The four-terminal Kelvin connection is essential to achieving the stated precision at the resistance values covered by the HPCR4T. In the range of 0.5mΩ to 4mΩ, the resistance of solder joints, PCB traces, and lead lengths becomes a meaningful fraction of the element resistance itself, and any two-terminal measurement will incorporate those parasitic contributions into the reading. The HPCR4T provides two dedicated current terminals that carry the full load current through the manganin element, and two separate sense terminals that connect directly to the element body upstream of the current contacts. Because no current flows in the sense leads during measurement, their resistance contributes no voltage drop and no error to the reading. This arrangement allows the ±0.5% tolerance to be realised in circuit at all resistance values in the series, which would be unachievable with a standard two-terminal construction at these impedance levels.
Copper manganin is selected as the resistive material for its uniquely low and stable temperature coefficient of resistance. The HPCR4T achieves a TCR of no more than ±30 ppm/°C, meaning that even as the element self-heats under high continuous current, the change in resistance remains tightly bounded and the current measurement error introduced by thermal effects is kept to a minimum. The non-inductive winding configuration of the manganin element preserves low inductance across the operating frequency range, ensuring that the component accurately reproduces the instantaneous current waveform in pulsed and switched-current circuits without the reactive impedance that a conventional wirewound shunt of equivalent resistance would introduce.
Long-term stability is a defining characteristic of the HPCR4T, with a resistance shift of no more than ±0.1% confirmed after stability testing — a result that distinguishes it from general-purpose cement resistors and confirms its suitability for measurement systems where the shunt value must remain reliably within calibration over extended service intervals. Load life performance is rated at ±1.0% maximum resistance change over 500 hours at rated power with a 1.5-hour on and 30-minute off duty cycle, and short-time overload at 2.5 times rated power for five seconds is held within ±0.5%. The dielectric withstanding voltage of AC 1500V for one minute and the insulation resistance of 20 MΩ minimum at DC 500V confirm suitability for industrial line-voltage environments where the sense circuit may be referenced to a different potential from the current-carrying path.
HPCR4T Series High Power Four-Terminal Precision Current Sensing Resistors Specifications
A practical overview for engineers and procurement teams evaluating resistive solutions.
Model: HPCR4T
Resistor type: Current sensing
Description: Through Hole
Rated Current: 35-65A
Resistance (Ω): 0.5m-4m
Tolerance (%): ±0.5, ±1
TCR (ppm/C): 30
Applications of the HPCR4T Series High Power Four-Terminal Precision Current Sensing Resistors
Where RARA metal clad resistors are deployed in the field.
Frequency converters and variable frequency drives — high-current phase and DC bus sensing in industrial motor drives carrying tens of amperes continuously, where the four-terminal Kelvin connection eliminates contact resistance error and the manganin element’s low inductance accurately reproduces fast-changing current waveforms at drive switching frequencies.
Switch-mode power supplies and high-current DC-DC converters — precision output current measurement for current-mode control loops, overcurrent protection thresholds, and load monitoring in high-power industrial and telecom SMPS designs where the HPCR4T’s rated current capacity of up to 70A covers the full load range without requiring a parallel shunt arrangement.
Power modules and integrated power assemblies — four-terminal shunt elements embedded within power module assemblies, where the cement-encased ceramic body provides mechanical robustness and the Kelvin sense terminals are routed independently to the control or measurement circuit without sharing the high-current path.
EV charging stations and on-board chargers — precision current monitoring in electric vehicle charging infrastructure and vehicle-side on-board charger circuits, where continuous currents of 35A to 65A and the ±30 ppm/°C TCR combine to maintain measurement accuracy across the temperature range of outdoor charging installations and automotive underbonnet environments.
Traction inverters and regenerative drive systems — DC link and phase current sensing in traction drive inverters, regenerative braking systems, and industrial servo drives, where the high rated current, low sub-milliohm resistance values, and 2.5× short-time overload capability handle the peak currents present during acceleration and regenerative braking events without resistance degradation.
Industrial battery management systems and energy storage — charge and discharge current measurement in large-format battery management units and grid-connected energy storage inverters, where the long-term stability specification of ±0.1% and the four-terminal construction maintain calibration-grade current measurement accuracy over the extended service intervals required in stationary energy storage installations.
Precision power analysers and energy metering — high-current reference shunt elements in revenue-grade power analysers, sub-metering equipment, and power quality instruments, where the Kelvin connection, tight tolerance, and stable TCR of the HPCR4T provide a well-characterised shunt resistance capable of supporting traceable current measurement at high continuous current levels.
Welding equipment and plasma power supplies — continuous high-current sensing in inverter-based welding machines and plasma cutting power supplies, where the robust cement-sealed construction and high pulse power capability withstand the repetitive high-current transients inherent in arc welding and plasma cutting duty cycles.
Test and measurement systems — high-current reference shunt elements in electronic loads, source-measure units, and automated test equipment requiring stable, accurately characterised milliohm resistance with four-terminal sense access at current levels that exceed the ratings of surface-mount precision shunt alternatives.
Related Products of the HPCR4T Series High Power Four-Terminal Precision Current Sensing Resistors
Model: RMF
Resistor type: Precision
Description: High power 4 terminal
Power Rating: 10W
Resistance (Ω): 0.5~200
Tolerance (%): ±0.1~±5
TCR (ppm/C): 5, 10, 15, 20, 30
Model: PCR4T
Resistor type: Current sensing
Description: Through Hole
Power Rating: 3W
Resistance (Ω): 1m-10m
Tolerance (%): ±0.5, ±1, ±5
TCR (ppm/C): 30
Model: AH
Resistor type: Current sensing
Description: Four terminal precision
Power Rating: 3W, 10W
Resistance (Ω): 1m~100
Tolerance (%): ±0.1, ±5, ±1
TCR (ppm/C): 10
Model: PBV, PBH
Resistor type: Current sensing
Description: Four terminal precision
Power Rating: 3W, 10W
Resistance (Ω): 0.5m~100m
Tolerance (%): ±0.5, ±1, ±5
TCR (ppm/C): 30, 50
Why Choose RARA Current Sensing Resistors
What sets RARA apart for engineers and procurement managers in industrial and automotive markets.
01
8 Sub-Categories
No other single supplier covers AEC-Q200 chip shunts, milliohm precision types, four-terminal Kelvin shunts, power metering, and 12,000A panel shunts under one ISO-certified roof.
02
Extreme Precision
HPS, UHPS, and PSS precision shunts deliver ±0.05% tolerance and 3 ppm/°C TCR — meeting the accuracy demands of EV battery coulomb counting, precision power analyzers, and billing-grade energy metering.
03
Automotive Qualified
Multiple AEC-Q200 certified models (BCS, LRA, ECS, BWR, TCS, PCBS) with IATF 16949 manufacturing certification — covering EV battery management, motor control, and charging applications.
04
Global Track Record
Trusted by Tesla, GM Korea, Proterra, Siemens, Rockwell, and Schneider Electric — deployed in EV powertrains, industrial drives, and utility metering systems across six continents.
