Product Introduction
The BSBC8V-250C is a high-performance 250A DC contactor designed specifically for electric vehicle (EV) applications. With its ceramic-sealed design, the contactor is able to withstand high-voltage environments up to 1000VDC. Ideal for use in EV battery packs, motor controllers, and inverter-side switching, the BSBC8V-250C provides exceptional reliability and long electrical life, offering secure isolation and protection under high current conditions.
Product Features
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250A Continuous Current: Suitable for high-current switching in EV applications.
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Rated Voltage Up to 1000VDC: Ideal for use in high-voltage EV systems.
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Ceramic Sealed Construction: Provides superior insulation, arc suppression, and long-term reliability.
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Overload and Short-Circuit Tolerance: Can handle up to 2000A for a single operation and withstand 600A for 120s overload.
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Fast Switching: Operate time ≤30ms, release time ≤10ms, bounce ≤5ms for precise control.
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Auxiliary Contact: Provides feedback on contactor position (SPST-NO 1 Form A).
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Energy-Efficient: Dual coil design for low holding power (6W), ideal for battery management.
Typical Applications
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Battery Disconnect Unit (BDU) for electric vehicles (EVs)
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Inverter and Powertrain Switching
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Energy Storage Systems (ESS) for hybrid electric vehicle (HEV) setups
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Pre-Charge Circuits for EV and ESS
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Emergency Isolation in high-voltage EV battery modules
Summary of Technical Parameters
| Parameter | Value |
|---|---|
| Model | BSBC8V-500E |
| Rated Current | 500A (≥200 mm² cable) |
| Rated Voltage | 12–1000VDC |
| Max Breaking Current | 2000A @ 1000VDC (1 op) |
| Contact Type | SPST-NO (1 Form A) |
| Auxiliary Contact | SPST-NO (1 Form A), 6VDC / 0.1A |
| Contact Resistance | ≤0.3 mΩ @ 500A |
| Overload Endurance | 600A/120s, 900A/30s, 1000A/10s |
| Electrical Life | 100 ops @ 500A 1000VDC 200 ops @ 400A 1000VDC 500 ops @ 200A 1000VDC 1 op @ 2000A 1000VDC |
| Mechanical Life | 200,000 operations |
| Coil Voltage | 12VDC / 24VDC (dual-coil) |
| Coil Resistance | 4Ω & 24Ω (12V) / 16Ω & 96Ω (24V) |
| Power Consumption | 36W (pull-in), 6W (holding) |
| Operate / Release Time | ≤30ms / ≤10ms |
| Bounce Time | ≤5ms |
| Vibration / Shock | 49 m/s² vibration, 196 m/s² shock |
| Short Circuit Tolerance | 8000A @ 5ms (no fire or explosion) |
| Working Temp | -40°C to +85°C |
| Mounting Orientation | Vertical |
| Weight | Approx. 400g ±15g |
Dimensional Drawing & Wiring Diagram
Connector Horizontal Lead-Out Type
Connector Vertical Lead-Out Type
FAQs About The BSBC8V-250A High Voltage DC Contactor
Q1: Can the BSBC8V-250C be used in 1000VDC EV systems?
A1: Yes, the BSBC8V-250C is rated for 1000VDC operation, making it perfect for high-voltage EV systems like battery packs and inverter-side switching.
Q2: Does this contactor include auxiliary contacts?
A2: No, the BSBC8V-250C doesn’t have auxiliary contacts.
Q3: What is the short-circuit protection for this contactor?
A3: 8000A @ 5ms for short-circuit protection without fire or explosion.
Precautions for Use
Installation Guidelines
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Use flat and spring washers for mounting to prevent loosening.
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Recommended torque for load terminals (M6 bolts): 6–8 N·m; body mounting (M5 screws): 3–4 N·m.
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Ensure copper bar flatness and proper hole size to avoid thread damage.
Electrical Load Protection
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Inductive loads (L/R ≥1ms): Use parallel surge suppression devices (TVS or varistors).
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Capacitive loads: Implement pre-charge circuits and control the closing voltage differential to ≤20V to prevent contact welding.
Coil Drive Protection
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For non-economizer models, install a TVS diode or varistor to suppress reverse EMF.
⚠️ Avoid using diodes for coil protection, as they will increase release time and reduce breaking capacity.
Environmental Guidelines
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Operating temperature range: -40°C to +85°C
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Do not install near heat sources (e.g., fuses, shunts) or strong magnetic fields (e.g., transformers).
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Store in dry, cool, non-corrosive environments.
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Shelf life: 12 months in original packaging.
Handling Notes
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Do not reuse the contactor if dropped or damaged.
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Keep terminal pads free of grease or foreign matter to avoid overheating.