Looking for an actual PICTURE of the HV Battery Contactors?

[Jimrpa]

I’m trying to find an actual photograph (preferably with some kind of guidance on dimensions) for the HV Contactors. Not the assembly they’re in (I.e. not a picture of the HVJB or something). The actual (presumably big pieces of copper) Contactors.

Sponsored

 

[Logal727]

I’m trying to find an actual photograph (preferably with some kind of guidance on dimensions) for the HV Contactors. Not the assembly they’re in (I.e. not a picture of the HVJB or something). The actual (presumably big pieces of copper) Contactors.

They are encased in ceramic aren’t they?

 

[Blue highway]

I'd like to see that too. The relays are the white cylinders in this picture.

 

[Jimrpa]

They are encased in ceramic aren’t they?

I do not know. I don’t even know where they’re located. I do remember seeing some copper “bars” in the Sandy Monroe disassembly video a long time ago.

 

[Logal727]

I do not know. I don’t even know where they’re located. I do remember seeing some copper “bars” in the Sandy Monroe disassembly video a long time ago.

They are inside those white cap looking things

 

[Jimrpa]

They are inside those white cap looking things

So, it’s the relays (the “white cap looking things”) that are overheating?

 

[Blue highway]

So, it’s the relays (the “white cap looking things”) that are overheating?

yes

 

[Logal727]

So, it’s the relays (the “white cap looking things”) that are overheating?

It's contained to prevent oxygen from getting in and increasing the chance of an air gap, which is what causes arcing.

 

[Ochroma]

I haven't seen anyone post in this forum yet the specifics of the main HV contactors (white cylinders) that have been the juicy topic of discussion.

Here's a link to the general product offering for these contactors: https://www.te.com/usa-en/products/...ge-contactors-evc-500-500l.html?tab=pgp-story
And a link to one of the specific part numbers that are used in the car, with a technical datasheet drawing: https://www.te.com/usa-en/product-2342963-4.html

 

[p-zilla]

Look at the Sandy Munro teardown video.. he shows the contactors and the HVBJB internals.

 

[Blue highway]

Look at the Sandy Munro teardown video.. he shows the contactors and the HVBJB internals.
[/QUO

I haven't seen anyone post in this forum yet the specifics of the main HV contactors (white cylinders) that have been the juicy topic of discussion.

Here's a link to the general product offering for these contactors: https://www.te.com/usa-en/products/...ge-contactors-evc-500-500l.html?tab=pgp-story
And a link to one of the specific part numbers that are used in the car, with a technical datasheet drawing: https://www.te.com/usa-en/product-2342963-4.html

From the spec sheet :

• Contactor arrangement: Main contacts SPST–NO-DM (1 Form X)
• Voltage rating (max): 900 VDC
• Continuous current rating: 500 Amps at 85 °C
• Break current at 320 VDC: 2,000, 1 cycle
• Coil resistance: EVC 500 contactor = 3.14 ohms

An SR RWD car draws less than 500A foot on the floor. (198kW / 400v = 495A) Presumably, the contactor could support full power output indefinitely.

By contrast a GT draws a lot more than 500A foot on the floor. (358kW / 400v = 895A). Foot on the floor is not continuous, but you can see where it is in a gray zone for durability... (Anyone see a possible root cause for the 5 second rule for GT cars?)

 

[Jimbo]

From the spec sheet :

• Contactor arrangement: Main contacts SPST–NO-DM (1 Form X)
• Voltage rating (max): 900 VDC
• Continuous current rating: 500 Amps at 85 °C
• Break current at 320 VDC: 2,000, 1 cycle
• Coil resistance: EVC 500 contactor = 3.14 ohms

An SR RWD car draws less than 500A foot on the floor. (198kW / 400v = 495A) Presumably, the contactor could support full power output indefinitely.

By contrast a GT draws a lot more than 500A foot on the floor. (358kW / 400v = 895A). Foot on the floor is not continuous, but you can see where it is in a gray zone for durability... (Anyone see a possible root cause for the 5 second rule for GT cars?)

There's four in the HVBJB, though, right? I presume (perhaps incorrectly) that more than one gets used at a time (one per motor?)

 

[Blue highway]

There's four in the HVBJB, though, right? I presume (perhaps incorrectly) that more than one gets used at a time (one per motor?)

maybe. That would keep the current just under the limit. But the vast over representation of GT's in the failure group suggests something else.

I suspect they disconnect both the + and - poles from the car which takes two relays. I've also guessed that the other set is for charging so that is isolated as well. now you need four relays, which is what is there. You really don't want 400v at the charge connector when the car is on.

I've not seen the full diagram for this, (if someone has it please post it)

 

[Mach-Lee]

The contacts are inside the white plastic cans. You'd have to cut them open to see the actual contacts inside.

There's four in the HVBJB, though, right? I presume (perhaps incorrectly) that more than one gets used at a time (one per motor?)

maybe. That would keep the current just under the limit. But the vast over representation of GT's in the failure group suggests something else.

I suspect they disconnect both the + and - poles from the car which takes two relays. I've also guessed that the other set is for charging so that is isolated as well. now you need four relays, which is what is there. You really don't want 400v at the charge connector when the car is on.

I've not seen the full diagram for this, (if someone has it please post it)

There are six contactors in the HVBJB:

1. Main +
2. Main -
3. DCFC +
4. DCFC -
5. Pre-charge
6. Auxiliary (DC/DC, A/C, heat, L2 charging)

1-4 are the big white ones. While driving only 1, 2, and 6 are closed.

 

[strangeengine]

Somewhere in one of these never-ending threads is a video from a contactor company that shows them operating. It's basically just a gigantic relay.

Sponsored