Sensata Gigavac GV221CAB Overview
The Sensata Gigavac GV221CAB is a GV22 Series hermetically sealed DC power contactor designed for high-voltage switching in EV battery packs, charging systems, energy storage equipment, and industrial DC power systems. This model is configured with a 200 A current rating, 800VDC rated switching voltage, a 24VDC coil, 15 inch flying leads, an SPST-NO main contact, and an SPST-NO normally open auxiliary contact. 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 |
GV221CAB |
| Series |
GV22 |
| Product Type |
Hermetically Sealed DC Power Contactor |
| Mounting Type |
Upright Chassis Mount |
| Coil Voltage |
24VDC |
| Contact Form |
SPST-NO, 1 Form X Main Contact |
| Contact Rating Current |
200 A |
| Switching Voltage |
800VDC Rated |
| Termination Style |
Stud, Wire Leads |
| Coil Termination |
15 inch / 38 cm Flying Leads |
| Power Terminals |
M8x1.25 Stud Terminals |
| Auxiliary Contact |
SPST-NO, Normally Open, Mechanically Linked |
| Auxiliary Contact Rating |
2A at 24VDC Resistive Load |
| Operating Temperature |
-55°C to +85°C |
| Must Operate Voltage |
16 VDC |
| Must Release Voltage |
0.5 VDC |
| Operate Time |
20 ms Max |
| Release Time |
12 ms Max |
| Coil Current |
280 mA |
| Coil Power |
6.8 W |
| Coil Resistance |
85.71 Ohms |
| Mechanical Life |
1,000,000 Cycles |
| Contact Resistance |
0.4 mOhm Max; 0.3 mOhm Typical |
| Environmental Seal |
Hermetically Sealed, Exceeds IP67 and IP69K |
| Typical Weight |
Approx. 0.44 kg / 0.97 lb for upright mount version |
Product Description
The Sensata Gigavac GV221CAB is a compact 200 A DC contactor for systems that require reliable high-voltage switching, sealed construction, and practical harness wiring. As part of the GV22 Series, it is designed for 800VDC class power control applications where dependable isolation and controlled load connection are required. It is suitable for electric vehicles, hybrid vehicles, battery energy storage systems, DC charging equipment, industrial battery packs, power conversion cabinets, marine DC systems, material handling equipment, and renewable energy equipment.
GV221CAB uses a normally open main contact. In the de-energized state, the main circuit is open and the load is isolated. When the 24VDC coil is energized, the contactor closes and current flows through the main power terminals. When coil power is removed, the main contact opens again. This behavior makes GV221CAB suitable for main battery disconnect, charge contactor, discharge contactor, inverter input control, DC bus switching, and high-voltage load isolation in properly engineered systems.
The complete model number should be used in product listings and backend records. “GV22” identifies the 200 A, 800VDC contactor family. The “1” indicates upright mounting. The “C” indicates the 24VDC coil version with internal coil suppression. The “A” indicates 15 inch flying leads. The final “B” indicates an SPST normally open auxiliary contact. This distinction matters because similar GV22 models may use 12VDC or 48VDC coils, PCB pins, no auxiliary contact, or normally closed auxiliary contacts.
Key Features
- 200 A current rating for high-voltage DC switching applications.
- 800VDC rated switching voltage for EV, ESS, charging, and industrial systems.
- 24VDC coil for common battery management and industrial control circuits.
- SPST-NO main contact for controlled power connection and isolation.
- 15 inch flying leads for compact harness and cabinet wiring.
- SPST-NO auxiliary contact for contactor state feedback.
- Hermetically sealed construction for harsh operating environments.
- Built-in coil suppression for simplified control circuit design.
- Upright mount format with M8 power terminal connection.
- Can be mounted in any position and exceeds IP67 and IP69K sealing requirements.
Applications
The Sensata Gigavac GV221CAB is commonly used in EV battery packs, hybrid vehicle systems, energy storage cabinets, DC charging systems, power distribution units, industrial DC buses, test benches, marine electrical systems, and renewable energy equipment. Its 200 A current rating makes it useful for medium-power high-voltage circuits where a 400 A or 500 A contactor would be oversized.
The normally open auxiliary contact can be used by a battery management system, vehicle controller, charger controller, or industrial control unit to monitor contactor state. Because the auxiliary contact is mechanically linked to the main power contacts, it provides useful feedback for startup sequencing, interlock logic, fault diagnostics, and status confirmation. The auxiliary contact is a signal contact and should not be used as a main power switching path.
Design Notes
The 800VDC and 24VDC values describe separate electrical circuits. The 800VDC rating applies to the main contact/load circuit and describes the high-voltage DC circuit the contactor is designed to switch. The 24VDC rating applies to the coil/control circuit that actuates the contactor. A system can use a 24V controller, BMS output, or relay driver to operate the coil while the main contacts switch a much higher DC bus.
GV221CAB includes internal coil suppression. Coil drive should follow the product requirements, and pickup voltage should be applied properly during testing rather than slowly ramped from zero. Adding external diodes across the coil can affect release time and switching performance, so suppression changes should be reviewed carefully.
For capacitive loads such as inverter inputs, DC link capacitors, chargers, 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 size, insulation spacing, thermal rise, current direction, enclosure protection, and fault current behavior.
Why Choose Sensata Gigavac GV221CAB
GV221CAB is a strong choice when a system needs a sealed 200 A, 800VDC contactor with 24V control, short flying leads, and normally open auxiliary feedback. Compared with PCB pin versions, the wire lead configuration is convenient for harness-based vehicle and cabinet installations. Compared with no-auxiliary versions, GV221CAB provides a built-in feedback contact for diagnostics and control confirmation.
For backend product listings, write the full name as Sensata Gigavac GV221CAB. Avoid shortening it to GV22 or GV221, because related models may use different coil voltages, mounting styles, PCB pins, or auxiliary contact configurations. GV221CAB specifically identifies the upright mount, 24VDC coil, 15 inch lead, normally open auxiliary version.
FAQ
Is GV221CAB an 800V or 24V contactor?
It uses both values for different circuits. The main contacts switch DC loads at 800VDC class voltage, while the coil/control circuit is 24VDC.
What is the current rating of GV221CAB?
GV221CAB is rated for 200 A continuous current.
Does GV221CAB include an auxiliary contact?
Yes. The final B in GV221CAB indicates an SPST normally open auxiliary contact.
What does the A mean in GV221CAB?
The A indicates 15 inch, or 38 cm, flying leads for the coil and auxiliary wiring.
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