Product Introduction
The BSBC8V-500 is a high-reliability 500A high voltage DC contactor tailored for electric vehicle (EV) applications. It features a ceramic-sealed, gas-filled chamber for safe arc suppression and extended electrical endurance. Rated for up to 1000VDC, this contactor ensures secure disconnection in EV main circuits, battery modules, and powertrain systems. With a robust overload capacity and a dual-coil energy-saving design, the C8V-500 guarantees reliable performance in the demanding environments of e-mobility platforms.
Product Features
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Rated 500A @ 1000VDC: Ideal for EV high-voltage main circuit control.
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Ceramic Gas-Sealed Housing: Prevents arc escape and environmental contamination.
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Heavy Load Tolerance:
– 600A for 120s
– 900A for 30s
– 1000A for 10s -
Auxiliary Contact Built-in: 1 Form A SPST-NO for real-time monitoring and protection systems.
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Compact and Lightweight: Approx. 400g with connector terminals, ideal for EV battery compartments.
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Non-polar Load Side: Simplifies installation in DC power loops.
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Dual Coil Drive: 36W pull-in and 6W holding power for efficient operation.
Typical Applications
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Electric Vehicle Battery Disconnects (BDU, HV Box)
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Pre-charge Circuit Control
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High Voltage Traction System Switching
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Motor Controller Protection
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EV Charging & Discharging Loops
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
FAQs About The BSBC8P-400A High Voltage DC Contactor
Q1: Is the BSBC8V-500 suitable for continuous 1000VDC operation?
A1: Yes. It is rated for continuous use at 500A 1000VDC, with proven endurance in EV-grade switching.
Q2: What is the peak short-circuit tolerance of this contactor?
A2: The C8V-500 withstands 2000A at 1000VDC for 1 operation, and has anti-short circuit capability at 8000A / 5ms without damage.
Q3: Does the contactor have polarity requirements?
A3: The load and auxiliary terminals are non-polar, but the coil is polarized and must be connected accordingly.
Q4: Is there auxiliary feedback for monitoring?
A4: Yes. It includes a 1 Form A auxiliary contact for logic feedback, status display, or interlock control.
Q5: What role does this high voltage DC contactor play in an EV system?
A5: It acts as the main circuit switch between the battery and powertrain/inverter. It ensures safe disconnection during faults, allows pre-charge control, and supports high voltage isolation during charging and maintenance.
Precautions for Use
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Use flat + spring washers for mounting.
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Recommended torque:
– Load terminals (M6): 8–10 N·m
– Body mounting (M5): 3–4 N·m -
For inductive loads (L/R ≥1ms), install TVS or varistor in parallel to protect contacts.
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For capacitive loads, ensure pre-charge control and closing voltage ≤20V to avoid contact fusion.
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Do not use diodes for coil suppression; use TVS or varistor to avoid extended release time.
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Temperature range: -40°C to +85°C; do not exceed or use where condensation or icing may occur.
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Avoid magnetic interference (e.g., near transformers or magnets) and heat sources (e.g., fuses or shunts).
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Do not reuse if dropped or damaged.
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Store in dry, shaded, and gas-free environments. Shelf life: 12 months.