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UL, CE, and RoHS compliant high-voltage DC contactors, magnetic relays, and industrial switching assemblies tailored for Indian OEM charging station integration.
Custom-built electromechanical components engineered to withstand ambient heat up to 55°C, severe voltage fluctuations, and continuous heavy-load DC fast charging cycles.
Utilizing inert gas fill (hydrogen/nitrogen blend) and epoxy-sealed ceramic contact chambers, our contactors eliminate electrical arcing within milliseconds, preventing contact welding during emergency DC cutoffs.
Engineered with Class H (180°C) magnet wire and integrated PWM economizer circuits, reducing coil hold power consumption by up to 70% while keeping junction temperatures cool under intense heat in Indian charger cabinets.
Advanced magnetic blowout structures allow seamless bi-directional power flow control, essential for Vehicle-to-Grid (V2G) applications and dual-gun CCS2 / CHAdeMO DC fast-charging terminals.
As India accelerates its electric mobility revolution under the National Electric Mobility Mission and aggressive state-level EV policies, the expansion of high-power DC Fast Charging (DCFC) networks along national highways, urban hubs, and fleet depots has created unprecedented demand for resilient, high-voltage switching components. Unlike standard AC distribution, breaking direct current at 750V to 1000V DC introduces intense electrical arcing because direct current lacks a natural zero-voltage crossing point. In the hot, dusty, and thermally demanding environments typical of Indian cities—where internal power distribution cabinet temperatures routinely exceed 60°C—standard contactors quickly experience contact erosion, elevated thermal resistance, and catastrophic contact welding.
When an EV charging session terminates—or when an emergency shutdown (EPO) is triggered—the DC contactor must instantaneously break continuous currents upwards of 300A to 400A. The resulting electric arc generates localized plasma temperatures exceeding 5,000 Kelvin. Our high-voltage DC contactors employ twin permanent magnetic blowout magnets surrounding a hermetically sealed ceramic contact chamber.
The magnetic field exerts a Lorentz force on the ionized arc path, rapidly stretching and forcing the arc into specialized arc chutes or gas-filled chambers. By utilizing high-dielectric inert gas under pressure, electron mobility is choked within 5 to 10 milliseconds, ensuring zero carbon deposit buildup and maintaining minimal contact resistance (< 0.3 mΩ) throughout the contactor’s lifespan.
A critical engineering failure mode in Indian EVSE deployment is thermal runaway caused by high ambient temperatures combined with high I²R copper losses. Standard European or North American contactors designed for 40°C maximum ambient conditions require severe current derating when deployed in Rajasthan, New Delhi, or Gujarat, where ambient shade temperatures surpass 48°C.
Our OEM export series intended for Indian system integrators features solid silver-alloy contacts (AgSnO₂) bonded to ultra-pure oxygen-free copper (OFC) busbars. Combined with high-efficiency PWM electronic coil drivers, holding power is reduced from 30W during pick-up to less than 2.5W during continuous operation. This dramatically decreases internal cabinet heat generation, allowing continuous 100% duty cycle rating at 50°C ambient without thermal tripping or insulation breakdown.
In many Indian charging stations, DC power is sourced directly from rooftop solar arrays coupled with Battery Energy Storage Systems (BESS) alongside grid power. This multi-source DC microgrid design introduces variable short-circuit capacities and rapid voltage transients. DC contactors deployed as main battery disconnects or DC bus couplers must possess high peak impulse withstand voltages (Uimp ≥ 8kV) and high short-circuit breaking capabilities.
Furthermore, integrated mechanical or mirror-type auxiliary contacts provide real-time status feedback to the charging station’s Central Management System (CMS) via Modbus/CAN bus. This guarantees that power modules are completely isolated before the charging gun latch mechanism unlocks, ensuring strict adherence to AIS-138 and IEC 61851-23 safety standards for public EVSE installation in India.
Targeted electromechanical solutions tailored for India's diverse electric vehicle infrastructure landscape.
Installed inside dual-gun CCS2 DC fast-charging cabinets along interstate corridors (e.g., Delhi-Jaipur Highway, Bengaluru-Chennai Expressway). Our 200A to 400A gas-filled contactors switch high-voltage DC buses safely while resisting heavy dust influx and monsoon humidity.
Heavy-duty public transport depots in metro cities such as Mumbai (BEST), Delhi (DTC), and Bengaluru (BMTC) utilize automated high-current pantograph and plug-in chargers. Our 500A continuous rated DC contactors handle frequent high-power charge cycles with zero maintenance.
Rapid battery swapping hubs serving hyper-local logistics (Delhivery, Zomato, Swiggy) require compact, high-cycle DC switching matrix relays (100A to 150A) for multi-bay battery rack management, ensuring instantaneous pre-charge and main connection isolation.
Evaluate key technical specifications across switching architectures for optimal EVSE system integration.
| Specification Feature | Altran Hermetic Epoxy/Gas-Filled DC Series | Standard Open-Frame Air DC Contactors | Conventional AC Definite Purpose Contactors |
|---|---|---|---|
| Max Switching Voltage | Up to 1500 VDC | Up to 440 VDC | Up to 250 VDC (Unsafe for HV DC) |
| Arc Extinction Method | Magnetic Blowout + Inert Sealed Gas Chamber | Open-Air Magnetic Arc Chutes | None (Air Break Only) |
| Contact Resistance | < 0.3 mΩ (Constant over lifespan) | 1.2 - 2.5 mΩ (Increases due to oxidation) | 3.0+ mΩ (High oxidation risk) |
| Operating Ambient Temp | -40°C to +85°C (Full rating up to 50°C) | -25°C to +40°C (Requires severe derating) | -20°C to +45°C |
| Ingress Protection (IP) | IP67 Sealed Contact Chamber | IP20 / Exposed Contacts | IP00 / Open Terminals |
| Electrical Lifespan | 150,000 Operations @ Full Load | 20,000 Operations | < 5,000 Operations on DC |
With engineering headquarters based in Sterling, Illinois, USA, and localized distribution networks spanning Europe, Asia, and North America, Altran Magnetics, LLC delivers battle-tested electrical switching components built to international OEM standards.
Our high-voltage DC contactors, EMI line filters, and solid-state relays undergo rigorous 100% automated end-of-line testing—including high-potential insulation testing, contact resistance measurement, and dynamic pick-up/drop-out voltage validation. By adhering to UL, cUL, CE, CSA, and RoHS compliance, we provide Indian Charge Point Operators (CPOs) and power electronics manufacturers with reliable component traceability, full material safety documentation, and localized engineering support.
Direct technical and commercial answers for electrical engineers, system integrators, and purchasing teams in India.
Consult with our application engineering team today to review your EVSE schematic, request customized busbar samples, or obtain volume export quotes for your Indian manufacturing operations.
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