Product Profile
The BSB C7-100A DC contactor is a 100-amp high voltage DC contactor featuring a sealed epoxy resin design that ensures stable performance in harsh environments. Designed for medium to high current switching applications, such as EV main circuit control, energy storage system switching, and photovoltaic integration, it offers a robust, non-polarity structure with UL, CE, and TUV certifications. With a maximum switching current of 1000A and low internal resistance of just 0.4 mΩ, it ensures both efficiency and safety.
Product Features
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Epoxy Sealed Structure: Fully enclosed construction protects the coil and contacts from oxidation and environmental degradation.
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High Interrupting Capacity: Supports up to 1000A switching current at 320VDC.
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Low Contact Resistance: Only 0.4 mΩ at 100A, improving energy efficiency and thermal performance.
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Flexible Coil Options: Available in 12V, 24V, and dual 12–24V energy-saving configurations.
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Non-Polarity Design: Simplifies wiring and reduces installation risk.
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Wide Environmental Compatibility: Works reliably from -40°C to +85°C with IP67-rated sealing.
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International Certification: Fully compliant with UL, CE, TUV, and RoHS.
Typical Applications
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Main relay in 100A-rated EV power distribution systems
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DC switching for mid-size to large BESS (battery energy storage systems)
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PV (photovoltaic) inverter system control circuits
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DC fast-charging modules requiring rapid disconnect
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Industrial power switching units
Summary of Technical Parameters
| Parameter | Value |
|---|---|
| Rated Current | 100A |
| Rated Voltage | 12–1000VDC |
| Main Contact Type | SPST-NO (1SH) |
| Contact Resistance | ≤0.4 mΩ |
| Max Switching Current | 1000A @ 320VDC |
| Dielectric Strength | DC3110V / AC2200V |
| Insulation Resistance | ≥1000 MΩ @ 1000VDC |
| Mechanical Life | 300,000 cycles |
| Capacitive Load Life | 250A (RC=1ms), 50,000 cycles |
| Operating Temperature | -40°C to +85°C |
| Coil Voltage Options | 12V / 24V / 12–24VDC (Economizer) |
| Mounting Orientation | Vertical / Horizontal |
| Auxiliary Contact (Optional) | NO / NC / None |
| Weight | ~190g–210g depending on version |
| IP Rating | IP67 |
| External Conductor Area | ≥35 mm² |
Dimensional Drawing & Wiring Diagram
Vertical type without economizer
Horizontal type without economizer
Vertical type with economizer
Frequently Asked Questions (FAQs) About The C7-100A DC Contactor
Q1: Does the C7-100A DC contactor have reverse surge protection?
A1: Only products equipped with a PWM economizer include a surge suppression circuit. If you choose a standard product without an economizer, you need to address the issue of counter-electromotive force (back EMF) from a design perspective.
Q2: What makes the C7-100A DC contactor suitable for EV systems?
A2: It offers low resistance, non-polarity design, wide voltage range, and high safety certifications.
Q3: How is it different from lower-current C7 models like 30A or 50A?
A3: The C7-100A DC contactor supports higher inrush and continuous current, with a reinforced design and thicker external conductor requirements (≥35 mm²).
Precautions for Use
Please follow these important precautions when using the C7-100A high voltage DC contactor to ensure safe and reliable operation:
Mechanical Installation
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Use spring washers when installing the contactor to prevent screws from loosening.
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Tighten the screws with a torque of 3–4 N·m. Exceeding the maximum torque can cause damage to the contactor’s casing.
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The main contacts and the control coil leads are non-polarized, meaning there are no polarity requirements for the main contact and the control coil terminals.
Wiring Guidelines
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Use wires ≥10 mm² for external connections to avoid overheating at the terminals.
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Polarity: The contactor is non-polar, simplifying installation and wiring.
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Avoid placing grease or debris on the terminal leads to prevent potential overheating.
Surge Protection & Capacitive Loads
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Economizer models come with a built-in reverse surge absorption circuit, eliminating the need for an external surge protector.
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For non-economizer models, a varistor or TVS diode rated at 1.5–2 times the coil voltage should be installed in parallel at the coil terminals for surge protection. Do not use diodes, as they may reduce the contactor’s breaking capacity.
Environmental Conditions
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Operating Temperature: -40°C to +85°C
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Avoid placing the contactor near a strong magnetic field (e.g., transformers or magnets) or heat-emitting components (e.g., fuses, shunt resistors).
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Altitude Limit: ≤4000 meters above sea level.
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IP Rating: IP67 (internal space sealed).
Switching and Life Expectations
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This contactor is a high-voltage DC switch, with limited electrical life. Once it reaches the end of its electrical life, it may fail to disconnect properly.
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Design the circuit to ensure the power is cut off within 1 second if the contactor fails.
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For resistive loads, apply the rated current directly. For inductive loads (L/R > 1ms), a parallel surge protection device is required.
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Coil Drive Power: The coil drive circuit must provide more power than the rated coil power to ensure proper operation.
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When the contactor is operated continuously at rated voltage, its coil temperature will rise, which could lead to increased resistance and voltage rise. To prevent malfunction, reduce load current, limit power-on duration, or use a coil voltage higher than the rated voltage.
Handling and Storage
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Do not use the contactor if it has been dropped or subjected to impact.
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Avoid exposure to corrosive gases or direct sunlight during storage.
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Storage Temperature: -40°C to +85°C, with a humidity range of 5%–85% RH.
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Shelf life: 12 months in original packaging.