Safety contactor HVC

high-powerelectromagneticelectromechanical

Overview
The TDK HVC (High-Voltage Contactor) series is engineered for high-voltage, high-current DC safety disconnection, in particular for lithium‑ion battery systems. The devices incorporate a gas‑filled ceramic arc chamber derived from gas tube technology to provide rapid, repeatable disconnection across industrial, automotive and energy storage applications.

Key statement
Gas-filled contactors for safety disconnection up to 1500 V DC and 750 A DC.

Product portfolio (summary table)
Series: HVC43 | HVC45 | HVC27 | HVC50
Current up to [A DC]: 250 | 300 | 500 | 750
Voltage up to [V DC]: 1000 | 1000 | 1000 | 1500
Construction: Single coil | Single coil | Single coil or dual coil | Dual coil
Bidirectional design: ✔ | ✔ | ✔ | ✔
Auxiliary contacts: With and without mechanical contact | Mechanical contact (under development) | Contact with Hall sensor (optional) | Mechanical contact
Size [mm] (l x w x h): 74.5 x 40.4 x 78.0 (w/o MC); 74.5 x 40.5 x 78.0 (with MC) | 74.3 x 42.5 x 86.5 | 92.5 x 44.0 x 89.0 | 107.3 x 94.2 x 141.0
Weight [g]: ~300 | ~390 | ~500 | ~1600

Function
The HVC design uses a movable armature inside a hermetically sealed, gas‑filled ceramic chamber. An electromagnet actuates the armature to open the circuit and interrupt high DC current. During opening an arc may form; the gas‑filled arc chamber and chamber geometry minimize arc duration and contact heating to ensure reliable interruption.

Features

• Fast, precise switching: Gas‑filled ceramic arc chamber provides short extinguishing times (typ. ~1.2 ms clear break) reducing contact heating and EMI compared to typical contactors.
• Operational advantages: Lower contact heating, reduced risk of sticking, lower EMI.
• Contactless stuck detection — Hall: Optional Hall sensor feedback available as NC or NO; >1 million switching cycles; tack‑welding resistant; ProFET technology offers short‑circuit robustness; Hall sensor senses indicator magnet pole and resists lateral stray fields.
• Mechanical stuck detection: Mechanical auxiliary contact linked to main contact (mirror contact), normally closed (NC), compliant with IEC60947‑4‑1 and IEC60947‑5‑1 where applicable.
• Single coil vs. dual coil: Single coil: no additional make current; operating power ≈6 W (0.5 A @ 12 V). Dual coil: high make power ≈38 W (3.2 A @ 12 V) for 80–120 ms, low holding power ≈4.2 W (0.35 A @ 12 V), hot‑restartable <1 s; dual coil increases lifetime by >50% in tests.
• Bipolar contacts: Bipolar contact design enables connection regardless of polarity — useful for assembly and for both charging/discharging without a second contactor.
• Reliability & certifications: Designed for >1 million mechanical operations where applicable; CE (Low Voltage Directive 2014/35/EC); UL 60947‑4‑1 (File No: E491412); ISO 9001, IATF 16949, ISO 14001 certified sites; AEC‑Q200 testing referenced; up to 1200 V DC and continuous current capability up to 750 A depending on model.

Applications (selected)

• DC chargers
• Electric and commercial vehicles
• Energy storage systems (ESS)
• Battery junction boxes

Documentation & product data
Model‑specific data sheets and product data are available for each HVC model and include nominal coil voltages, maximum operating voltages, continuous current ratings, coil type, auxiliary contact options and ordering codes.

Technical specifications

• Series designation: HVC series
• Operating voltage range (examples): up to 1000 V DC (HVC43 / HVC45 / HVC27), up to 1500 V DC (HVC50)
• Continuous operating current (examples): 250 A, 300 A, 500 A, 750 A (model dependent)
• Make/break extinction time (typ.): ~1.2 ms (clear break)
• Construction types: single coil, dual coil (model dependent)
• Auxiliary contact: mechanical contact options, Hall sensor feedback (optional)
• Bidirectional switching: yes (bipolar contacts)
• Typical sizes (l x w x h mm): see portfolio table above
• Typical weights (g): ~300 to ~1600 depending on model
• Standards & testing: IEC/UL/AEC‑Q200 references as applicable