Sensata Gigavac GV200CCB-1

The Sensata Gigavac GV200CCB-1 is a GV200 Series hermetically sealed DC power contactor designed for high-current switching in electric vehicles, battery systems, industrial DC equipment, and renewable energy power systems. This model is configured with a 500 A contact current rating, 800VDC maximum switching voltage, a 24VDC coil, stud and wire lead termination, and a normally open auxiliary contact. The 800VDC rating applies to the main power contacts, while the 24VDC rating applies to the coil/control circuit.

Product Description

The Sensata Gigavac GV200CCB-1 is a high-current DC contactor for demanding power switching applications. As part of the GV200 Series, it supports 500 A continuous current and DC switching up to 800VDC, making it suitable for electric vehicles, hybrid vehicles, battery energy storage systems, industrial battery packs, DC charging systems, marine power systems, and renewable energy equipment.

GV200CCB-1 uses a normally open main contact. In the de-energized state, the main power circuit is open. When the 24VDC coil is energized, the contactor closes and current flows through the main terminals. When coil power is removed, the main contact opens again and isolates the load. This makes the part useful as a main contactor, battery disconnect, charge contactor, discharge contactor, inverter input contactor, or DC load isolation device.

The complete model number is important. “GV200” identifies the 500 A contactor family. The “C” coil code identifies the 24VDC coil version. The following configuration code indicates the wire lead style used for control wiring. The final “B” indicates a normally open auxiliary contact. The “-1” suffix should be kept in the product title and backend records because it is part of the complete manufacturer ordering number.

Key Features

• 500 A current rating for high-power DC systems.
• 800VDC maximum switching voltage for EV, ESS, and industrial applications.
• 24VDC coil for common vehicle, battery, and industrial control systems.
• SPST-NO main contact for controlled load connection and isolation.
• Normally open auxiliary contact mechanically linked to the main power contacts.
• Hermetically sealed construction for reliable performance in harsh environments.
• Stud and wire lead termination style for practical system integration.
• Low coil power of about 2.3 W for efficient continuous operation.
• Fast operation with 20 ms operate time and 12 ms release time.
• Wide operating temperature range from -55°C to +85°C.

Applications

The Sensata Gigavac GV200CCB-1 is commonly used in electric vehicles, hybrid vehicle battery packs, battery energy storage systems, DC power distribution cabinets, industrial automation equipment, renewable energy systems, battery chargers, marine DC systems, heavy-duty vehicles, and high-current test equipment. Its 500 A rating makes it suitable for power paths where smaller 200 A or 350 A contactors are not enough.

The normally open auxiliary contact is useful for control feedback. A battery management system, vehicle control unit, or industrial controller can use the auxiliary contact to monitor whether the main contacts have changed state. This feedback contact is mechanically linked to the main contact system, but it is a low-current signal contact and must not be used for power switching.

Design Notes

The 800VDC and 24VDC values describe separate circuits. The 800VDC specification belongs to the main load circuit switched by the power contacts. The 24VDC specification belongs to the coil circuit that operates the contactor. A system may use a 24V controller output to energize the coil while the main terminals switch a much higher voltage battery or DC bus.

For systems with inverter inputs, DC link capacitors, or other capacitive loads, a pre-charge circuit is normally required before the main contactor closes. Pre-charge limits inrush current and helps protect the contactor, fuses, cables, busbars, and connected electronics. The auxiliary contact can support diagnostics and sequencing, but the system design should still include proper voltage, current, thermal, and fault protection.

Coil drive design should follow the GV200 Series requirements. The 24VDC coil has defined operate and release voltage limits, and the control supply must provide enough current for reliable operation under temperature and voltage variation. The contactor should also be installed with correct torque, cable sizing, creepage distance, and enclosure design for the target voltage and current.

Why Choose Sensata Gigavac GV200CCB-1

GV200CCB-1 is a strong option when a system needs a sealed 500 A DC contactor with 24V control and auxiliary contact feedback. Compared with lower-current contactors, the GV200 family provides higher continuous current capacity for demanding battery and vehicle applications. Compared with open-frame contactors, its hermetic sealed construction helps protect the contact system from dust, moisture, and harsh environments.

For product listings and replacement use, write the full model as Sensata Gigavac GV200CCB-1. Do not shorten it to GV200CCB, because the “-1” is part of the complete ordering code. Also avoid confusing this part with other GV200 versions using 12VDC or 48VDC coils, or with versions that have a different auxiliary contact configuration.

FAQ

Is GV200CCB-1 an 800V or 24V contactor?
It uses both values for different circuits. The main contacts switch DC loads up to 800VDC, while the coil/control circuit is 24VDC.

What is the current rating of GV200CCB-1?
GV200CCB-1 is rated for 500 A continuous current.

Is the main contact normally open?
Yes. The main power contact is SPST-NO, also described as 1 Form X.

Does GV200CCB-1 include an auxiliary contact?
Yes. This configuration includes a normally open auxiliary contact mechanically linked to the main contacts.