Sensata Gigavac GV200CBB-1
The Sensata Gigavac GV200CBB-1 is a GV200 Series hermetically sealed DC power contactor designed for high-current switching in electric vehicles, battery systems, industrial power equipment, and energy storage applications. This model is configured with a 500 A current rating, 800VDC maximum switching voltage, a 24VDC coil, 24 inch flying leads, an SPST-NO main contact, an SPST-NO normally open auxiliary contact, and high-voltage power contact construction. The 800VDC value refers to the main power/load circuit, while the 24VDC value refers to the coil/control circuit used to operate the contactor.
| Category |
Relays - Contactors, Electromechanical |
| Manufacturer |
Sensata-Gigavac Clean Energy |
| Manufacturer Product Number |
GV200CBB-1 |
| Series |
GV200 |
| Product Type |
Hermetically Sealed DC Power Contactor |
| Mounting Type |
Chassis Mount / Upright Flange |
| Coil Voltage |
24VDC |
| Contact Form |
SPST-NO, 1 Form X Main Contact |
| Contact Rating Current |
500 A |
| Switching Voltage |
12VDC to 800VDC |
| Termination Style |
Stud, Wire Leads |
| Coil Termination |
24 inch / 61 cm Flying Leads |
| Power Terminals |
M8x1.25 Stainless Steel Studs |
| Auxiliary Contact |
SPST-NO, Normally Open, Mechanically Linked |
| Auxiliary Contact Rating |
2A at 24VDC Resistive Load |
| Power Contact Option |
-1 High Voltage Contacts |
| Operating Temperature |
-55°C to +85°C |
| Must Operate Voltage |
16 VDC |
| Must Release Voltage |
2 VDC |
| Operate Time |
20 ms Max, 13 ms Typical |
| Release Time |
12 ms |
| Coil Current |
97 mA |
| Coil Power |
2.3 W |
| Coil Resistance |
247.42 Ohms |
| Mechanical Life |
1,000,000 Cycles |
| Contact Resistance |
0.4 mOhm Max; 0.15 to 0.3 mOhm Typical |
| Environmental Seal |
Hermetically Sealed, IP67 Rated |
| Typical Weight |
Approx. 0.38 kg / 0.84 lb |
Product Description
The Sensata Gigavac GV200CBB-1 is a 500 A DC contactor built for reliable switching in high-current DC power systems. As part of the GV200 Series, it combines compact size, sealed construction, low coil power, and high-voltage contact capability for applications that require dependable isolation and load control. It is suitable for electric vehicles, hybrid vehicles, battery energy storage systems, industrial battery packs, DC power distribution, renewable energy systems, marine power systems, and high-current test equipment.
GV200CBB-1 uses a normally open main contact. In the de-energized state, the main power circuit is open and the load is isolated. 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. This makes the GV200CBB-1 suitable for main battery disconnect, charge contactor, discharge contactor, inverter input control, DC bus switching, and high-current load isolation.
The complete model number is important. “GV200” identifies the 500 A, 800VDC contactor family. The first “C” indicates the 24VDC coil version with internal coil suppression. The second “B” indicates 24 inch flying leads. The final “B” indicates an SPST normally open auxiliary contact. The “-1” suffix indicates high-voltage power contacts and should remain in the product title, subtitle, and backend records.
Key Features
- 500 A current rating for demanding DC power switching applications.
- Switching capability from 12VDC up to 800VDC.
- 24VDC coil for common vehicle, battery, and industrial control systems.
- SPST-NO main contact for controlled power connection and isolation.
- Normally open auxiliary contact mechanically linked to the main contacts.
- 24 inch flying leads for practical wiring in battery packs and cabinets.
- High-voltage contact option identified by the “-1” suffix.
- Hermetically sealed construction for harsh operating environments.
- Low 2.3 W coil power for efficient continuous operation.
- UL508 recognized and CE conforming GV200 Series design.
Applications
The Sensata Gigavac GV200CBB-1 is commonly used in EV battery packs, hybrid vehicle systems, energy storage cabinets, DC charging systems, industrial DC buses, marine electrical systems, renewable energy systems, battery backup equipment, material handling vehicles, heavy-duty power equipment, and high-current DC test benches. Its 500 A rating makes it a practical option where 200 A, 350 A, or 400 A contactors do not provide enough current capacity.
The normally open auxiliary contact provides a feedback signal for control and diagnostic systems. A battery management system, vehicle controller, charger controller, or industrial control unit can use the auxiliary contact to confirm contactor state, sequence startup logic, or support interlock functions. The auxiliary contact is mechanically linked to the main contact system, but it is a low-current signal contact and must not be used as a power switching path.
Design Notes
The 800VDC and 24VDC values describe separate electrical circuits. The 800VDC rating applies to the main power contacts and describes the load-side DC voltage range the contactor is designed to switch. The 24VDC rating applies to the coil and describes the control voltage required to actuate the contactor. A system can use a 24V controller output to operate the coil while the main terminals switch a much higher DC bus.
GV200CBB-1 uses a dual-coil design. Both coils are used during pickup, and then the contactor transitions to low continuous hold power. The coil should be driven according to the product requirements, and pickup voltage should be applied properly during testing rather than slowly ramped from zero. The contactor includes internal coil suppression, so external suppression components should only be added after reviewing release-time and switching-performance effects.
For capacitive loads such as inverter inputs, DC link capacitors, and battery power electronics, a pre-charge circuit is normally required before closing the main contactor. Pre-charge limits inrush current and helps protect the contactor contacts, fuses, busbars, cables, and connected equipment. Final design should also verify terminal torque, cable sizing, insulation spacing, current direction, thermal rise, enclosure protection, and fault current behavior.
Why Choose Sensata Gigavac GV200CBB-1
GV200CBB-1 is a strong choice when a DC power system needs a sealed 500 A contactor with 24V control, 24 inch flying leads, normally open auxiliary feedback, and high-voltage contact construction. Compared with no-auxiliary versions, this model provides a dedicated feedback contact for the control system. Compared with 48 inch lead versions such as GV200CCB-1, the 24 inch lead length is better suited to layouts where the control harness is closer to the contactor.
For backend product listings, write the full name as Sensata Gigavac GV200CBB-1. Avoid shortening it to GV200CBB, because the “-1” suffix identifies the high-voltage contact option. Also avoid listing it as a generic GV200 contactor, because GV200 variants can differ by coil voltage, lead length, auxiliary contact type, PWM option, and power contact configuration.
FAQ
Is GV200CBB-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 GV200CBB-1?
GV200CBB-1 is rated for 500 A continuous current.
Does GV200CBB-1 include an auxiliary contact?
Yes. The final B in GV200CBB-1 indicates an SPST normally open auxiliary contact.
What does the second B mean in GV200CBB-1?
The second B indicates 24 inch, or 61 cm, flying leads. The final B indicates a normally open auxiliary contact.
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