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TDK TDK Electronics · TDK Europe
Up to 1200 V DC and 500 A

Gas-filled contactors for high voltage DC switching

TDK’s High-Voltage Contactor (HVC) Series is designed to meet the demands of high-voltage and high-current DC applications, especially for the disconnection for high-voltage lithium ion batteries. The hermetically sealed and gas-filled design is based on more than 80 years of experience with gas tube technology. The HVC series can be used in a wide range of applications where fast and reliable disconnection of high DC voltages is required.

Highly accurate and fast switching

[---Image_alt---] pic-switching-good

The TDK High-Voltage-Contactor Series extinguishes in 1.2 ms with clear break of current.

[---Image_alt---] pic-switching-bad

Typical contactor part will extinguish in 4.6 ms with lots of fluctuations, which heats up the main contacts.

The TDK HVC series provide a longer lifetime and increased reliability compared with existing products due to
  • Less heat on the contacts
  • Less likely to become stuck
  • Less EMI


Function

The basic design consists of a moveable armature inside a hermetically sealed, gas-filled chamber. The armature is moved by an electromagnet and opens the contact to interrupt the high current. During disconnection of a high DC voltage the generation of an arc is inevitable.

Features

Contactless stuck detection (auxiliary contact principle)

[---Image_alt---] pic-stuckdetection

Stuck Detection allows monitoring trouble-free switching. In case the contactor is stuck, the Aux COM and Aux NO wires will be short, hence the circuit is closed and the LED will be on (see example circuit). The Aux COM and Aux NC wires work the opposite way: the LED is off when the contactor is stuck. Stuck Detection is located at the opposite side, away from the arc-chamber to avoid influence from the main switching operation. Stuck Detection may also be known as state-control or auxiliary contact.

TDK design advantages

  • Contactless
  • No impact on breakting capability
  • No impact on dielectric strength


Temperatur and voltage sensor

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Integrated temperature sensor to ensure safe operation. Loose cables or bus-bars lead to increased contact resistance and therewith increased heat. The integrated temperature sensor indicates increased temperatures on the spot, ensuring a safe-operation.

Integrated voltage sensor allows direct measurement of voltage-drop at the main contact.

Temperature Sensor

  • Wires for the temperature sensor are connected to an NTC thermistor with a resistance of 10 kΩ (R25)
  • Measurable temperature range is −55 …+155 °C
  • NTC type: EPCOS B57551G1103+000 (RT No 8307). Tolerance = ±2%

Voltage Sensor

  • Voltage 1 and voltage 2 wires are connected to the main terminals via 1 MΩ resistors
  • Tolerance < 1%


Principle of the dual coil

 Single coil versus dual coil

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Single Coil

  • No additional current durig make (pick-up)
  • Operating power: 6 W, 0.5 A @ 12 V
  • No economizer required
  • Integrated coil termination
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Dual Coil

  • Power during make (pick-up) 28 W, 3.2 A @ 12 V during 80...120 ms
  • Operating power: 4.2 W (0.35 A) @ 12 V
  • Hot-restartability (<1 s)
  • Works like an economizer but without the disadvantages of a PWM circuit
  • Integrated coil termination


Dual coil

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Estimated service life for resistive loads

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  • High-voltage contactors are not designed to permanently switch under load
  • The device switches under load only in case of an emergency
  • Switching capability depends on voltage, current, inductance and resistance during break
  • Dual coil for increased lifetime of >50%: 3000 cycles with 300 A @ 450 V, 1000 cycles with 300 A @ 750 V

Bipolar contacts

HVC is designed bipolar, allowing connection independently of polarity. This is a great advantage during assembly and further allows charging and discharging of a battery without using a second contactor.

[---Image_alt---] pic-bipolar2

[---Image_alt---] pic-bipolar1


Reliability

[---Image_alt---] icon-switching
> 1 mil mechanical switching cycles
CE
CE marking, complies with EC Low Voltage Directive 2014/35/EC
ISO
All our sites are certified according the following standards:
ISO 9001, IATF 16949, ISO 14001
[---Image_alt---] icon-cruus
UL 60947-4-1 certified
File No: E491412
AFC Q200
Tested in accordance with
AEC Q-200, Rev. D
[---Image_alt---] icon-meter
Up to 1200 V DC operating voltage and 500 A DC continuous current capability.



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Download Step Files for HVC Series

  • A M6 inner thread and
  • B M8 outer thread
ZIP - 749.3 KB file_download Download

Products

PDF Nominal coil voltage (V DC) Max. operating voltage (V DC) Continuous operating current (A) Coil type Auxiliary contact Type               
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12 900 135 Single Coil No HVC135A-12
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24 900 135 Single Coil No HVC135A-24
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12 900 200 Single Coil No HVC200A-12
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24 900 200 Single Coil No HVC200A-24
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12 900 300 Single Coil Yes HVC300A-12S
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12 900 300 Single Coil No HVC300A-12
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24 900 300 Single Coil Yes HVC300A-24S
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24 900 300 Single Coil No HVC300A-24
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24 900 500 Single Coil No HVC500B-24
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12 900 200 Single Coil Yes HVC200A-12S
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24 900 200 Single Coil Yes HVC200A-24S
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12 900 500 Single Coil Yes HVC500B-12S
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12 900 500 Single Coil No HVC500B-12
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24 900 500 Single Coil Yes HVC500B-24S
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12 1000 200 Single Coil No HVC200A-12
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12 1000 200 Dual Coil No HVC200A-12E
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12 1000 200 Single Coil Yes HVC200A-12S
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12 1000 200 Dual Coil Yes HVC200A-12SE
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24 1000 200 Single Coil No HVC200A-24
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24 1000 200 Dual Coil No HVC200A-24E
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24 1000 200 Single Coil Yes HVC200A-24S
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24 1000 200 Dual Coil Yes HVC200A-24SE
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12 1000 300 Single Coil No HVC300A-12
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12 1000 300 Dual Coil No HVC300A-12E
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12 1000 300 Single Coil Yes HVC300A-12S
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12 1000 300 Dual Coil Yes HVC300A-12SE
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24 1000 300 Single Coil No HVC300A-24
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24 1000 300 Dual Coil No HVC300A-24E
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24 1000 300 Single Coil Yes HVC300A-24S
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24 1000 300 Dual Coil Yes HVC300A-24SE
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12 1000 500 Single Coil No HVC500B-12
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12 1000 500 Dual Coil No HVC500B-12E
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12 1000 500 Single Coil Yes HVC500B-12S
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12 1000 500 Dual Coil Yes HVC500B-12SE
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24 1000 500 Single Coil No HVC500B-24
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24 1000 500 Dual Coil No HVC500B-24E
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24 1000 500 Single Coil Yes HVC500B-24S
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24 1000 500 Dual Coil Yes HVC500B-24SE
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- - - --- --- Accessory Cover shield

In order to download up to 20 files together as zip, please mark them with the check box. To start the download, please click the Download button at the end of the list.

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Download Product Brief High Voltage Contactors

Content

  • High-voltage contactor series designed to meet the requirement of high-voltage DC switching applications.
  • The high-voltage contactors can be used in a wide range of applications where fast and reliable switching operations are required.
  • The hermetically sealed design exhibits excellent reliability in harsh environments.
PDF - 393.3 KB file_download Download

Applications

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DC charger for electrical and commercial vehiclesCommercial vehicles (trucks, busses, forklifts, special vehicles)Any application using a lithium ion battery (>400 V), such as solar inverters, USPs, etc.Electrical vehicle



HVC application: electrical vehicles

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Battery Management System (BMS)

  • Manages loading the battery, manages the battery and controls HVC. 
  • In an emergency the battery has to be disconnected from the load. Therefore, the battery disconnect unit (BDU) belongs or is part of the BMS.
  • The bipolar HVC allows charging (regenerative break) and discharging using the same contactor.

DC charger 

  • HVC is only connected during charging.
  • HVC is used to disconnect charger from the battery in case of an emergency.


HVC application: DC fast charger

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Description

  • Usually 2 DC outlets per charging pile in Europe 
  • Up to 2 contactors per outlet
  • Additional contactors for internal switching
  • Disconnection in case of malfunction or emergencies