“The transition to heavy-duty electric mobility requires charging infrastructure that delivers both high power and dependable operation,” said Helmut Pusch, CEO of Schaltbau GmbH Group. “The C330 megawatt charging contactor can safely switch the power levels required to recharge commercial vehicles within a typical driver break. With the C330, we enable customers to develop, equip and scale future-ready high-power charging systems that maximize charger availability, reduce costly downtime, and improve fleet utilization and total cost of ownership."

The Eddicy C330 is a single-pole, bi-directional DC contactor and the industry’s first rated for up to 1,500 V and continuous currents of up to 3,000 A. Featuring silver contact pills and an innovative contact system, the C330 achieves an industry-leading contact resistance of just 40 µOhm. This significantly reduces contact heating, power losses and cooling requirements. With separate contact systems for switching and current carrying, the C330 protects the main current path from the negative effects of electrical arcing, delivering outstanding safety, endurance and longevity.

The bi-directional contactor features an open-air-isolation concept with permanent magnetic arc blow-out that prevents rupture even under the most severe failure conditions. It can withstand short-circuit currents of up to 30,000 A for 5 ms without rupturing or damaging surrounding components.

The Eddicy C330 is designed for use in charging stations, energy storage systems and photovoltaic applications. CE, CCC and UL certifications are currently underway and are expected by September 2026.

Discover the Eddicy C330 contactor and meet Schaltbau’s experts at

• The Battery Show Europe (June 9–11, 2026)
  Messe Stuttgart, Hall 4, Booth E71
   
• Power2Drive Europe (June 23–25, 2026)
  ICM Munich, Hall C6, Booth C6.373

When it comes to heavy-duty freight and long-haul commercial vehicles, the opportunities and challenges of electrification are equally significant. Their impact on the climate is considerable: Heavy-duty vehicles (HDV) account for more than a quarter of greenhouse gas emissions (GHG) from road transport in the European Union alone and for over 6% of total EU GHG emissions.¹ Against the backdrop of global climate targets and the urgent need for decarbonization, electrifying road transport is essential. Megawatt charging is a key enabling technology to accelerate this shift before the end of the decade, particularly for vehicle classes that lack fixed routes or overnight depot-charging options (vs. e-buses or light commercial e-vehicles for inner-city or regional transport).

The promise of MCS: “Diesel-like” charging times

Although various high-power charging solutions with hundreds of kilowatts are already commercially available, multi-megawatt charging for heavy-duty vehicles is only now being developed and deployed by OEMs. While megawatt charging standards (MCS) level 2 targets up to 1.5 MW (1,500 A at up to 1,000V), MCS level 3 aims for up to 3 MW or more with current up to 3,000 A.

This could solve a critical pain point in electrification: charging times would align with typical work patterns and driver regulations. In the EU, for example, drivers are permitted 4.5 hours of driving before a mandatory 45-minute break. Under today’s CCS high-power charging standard, a 600 kWh truck charging from 10 to 80% state of charge (SoC) takes more than 70 minutes. With MCS, the same truck could charge in about 25 minutes.² Such charging window aligns with mandatory rest periods and extends ranges, supporting long-distance freight operations without disrupting route schedules.

Thermal challenges in megawatt charging

Yet, the path to HDV electrification faces formidable roadblocks in the form of regulatory, infrastructural, and technological challenges.³ One of the most critical technological challenges is the heat generated during the charging process. Excessive heat can damage cables, connectors, and other components, or even cause high-fault currents and fire hazards. Most importantly, batteries degrade much faster when repeatedly charged under hot conditions, reducing range, lifespan and the residual value of e-trucks.

But how does so much heat build up? Because every point of internal resistance along that long chain of connections from the charging port into the batteries causes energy losses and inefficiencies. And since megawatt-level chargers push 10 to 30 times more current than a typical home EV charger, and power losses grow quadratically with current, even small amounts of resistance generate significant heat.  

In a recent Schaltbau webinar, this was illustrated using the example of an average industry contactor with a 200 µOhm contact resistance. At CCS high-power charging levels, such contactor would generate 50 W of heat loss. In an MCS scenario at 1,500 A, this heat loss rises to 450 W. “That’s enormously high,” says Pavel Tomashev, Product Manager at Schaltbau. “That’s roughly the same heat as an iron or hairdryer set to medium power. You wouldn’t like to have several irons within a single switching cabinet⁴."

Technical solutions to overcoming MCS’ thermal challenges

So far, four main solutions have been developed to address thermal challenges in megawatt charging: (1) liquid cooling systems in stationary charging stations, (2) cooled charging harnesses that circulate a coolant directly through the power lines to keep the cables and connectors cool, (3) optimized component design to handle high loads without excessive resistance, and (4) advanced monitoring systems that continuously track temperature and other parameters, allowing for immediate shutdown if conditions become dangerously hot.

Despite the technical potential of cooling or monitoring systems, the business challenge remains: They have the potential to increase the total cost of ownership for heavy-duty EV operators, either by cutting into cargo (i.e. for additional cooling) or, more probable, into budget.

And additional operating costs add up quickly. If you increase charging current five-fold from 300 A to 1,500 A, power losses of a contactor with 200 µOhm grow quadratically by a factor of 25. As a result, the cost of wasted energy in the form of heat increases from around EUR 16 to EUR 362. Offsetting this with a cooling system would add roughly another EUR 340. Altogether, this amounts to about EUR 700/year, caused solely by inefficiencies at the contactor level.⁵

Choosing the right contactor for scalable and reliable MCS deployment

With the extremely high currents in MCS Levels 2 and 3, even the smallest resistance inefficiencies cause a significant portion of the energy intended for the powertrain or battery to dissipate as heat. At the contactor level, minimizing resistance is therefore imperative. Schaltbau has already introduced a new series of bi-directional contactors for Level 2 and Level 3 megawatt charging, designed to ensure efficient energy transfer and competitive total cost of ownership.

The new contactors for both stationary (C305 and C330) and mobile (C805 and C830) applications use silver alloy contact pills to achieve industry-leading contact resistance as low as 40 µOhm, delivering best-in-class performance with minimal contact warming. In practical terms: five times lower contact resistance (compared to average 200 µOhm contactors) also translates into five times lower costs.

The series also features a compact, open-isolation design that ensures robust protection under extreme conditions: permanent magnetic arc quenching without gas encapsulation prevents overheating and overpressure at all times. Even during severe short-circuit events, the contactors prevent system damage and component failure. For example, the C330 can withstand a short-term current of 15,000A for five milliseconds without contact welding — a critical safety benchmark for high-power systems. 

With separate contact systems for switching and current carrying, Schaltbau’s megawatt charging series also offers exceptional long-term contact resistance stability. Thanks to their compact size, these contactors are ideally suited to meet the stringent space requirements of megawatt charging stations, battery storage systems, e-mobility platforms, and other high-power industrial applications. With full bidirectionality, they are also ready for vehicle-to-grid (V2G) charging.

With the industry’s first contactors rated for 3,000A in accordance with the MCS standard, Schaltbau reaffirms its commitment to pioneering high-performance DC solutions that advance the electrification of energy and mobility.

Learn more about our solutions for megawatt charging and how we can support your electrification goals here.

References:

1. European Commission, Reducing CO₂ emissions from heavy-duty vehicles, 2023.
2. Schaltbau Webinar, How to overcome thermal challenges in megawatt charging, May 2025. Another similar calculation can be found in Froese, Michelle, Megawatt charging brings sub-30-minute charging to heavy-duty EVs, in: EV Engineering + Infrastructure, July 8, 2025.
3. For more details on the regulatory and infrastructural challenges, please see Schaltbau Blog, From diesel to direct current: Powering the electrification of commercial vehicles with megawatt charging, May 28, 2025.
4. Schaltbau Webinar, How to overcome thermal challenges in megawatt charging, May 2025.
5. Ibid. Schaltbau’s calculation is based on the average energy cost for industrial customers in Germany in 2024 and the rough estimation of cooling system capital and operating costs.

Building upon earlier successes of the C303 series, the final series production model leverages advanced open-air isolation technology, ensuring longer service life, higher system safety, and significantly reduced energy costs—up to 25% savings on total cost of ownership (TCO). Featuring enhanced arc suppression, ultra-low contact resistance, and full bidirectional operation, the C303 supports V2G readiness and secure integration into complex energy management systems. The final series version of the C303 has a streamlined design making for easier installation.

“The global demand for energy storage, EV infrastructure, and industrial electrification is projected to grow significantly in the coming decade,” said Helmut Pusch, CEO of Schaltbau GmbH Group. “With the C303 series, we’re responding not only with advanced technology but also with production capacity: engineered, manufactured, and also deployed in our state-of-the-art NExT Factory, where green processes, fully automated lines and multi-shift operations support not only the C303 but a broad range of advanced DC solutions, giving customers  the confidence that we can deliver high volumes without compromise on quality. This combination of German-made excellence, scale and innovation equips our partners to meet today’s extreme demand.”

Engineered for the toughest requirements in e-mobility and energy storage, the C303 combines 1,500 V switching capability with continuous currents up to 500 A in a compact, 0.42 kg design. Its open-air, magnetically blown arc system eliminates the need for gas encapsulation, reducing risk and extending service life even under demanding conditions. With ultra-low contact resistance of just 100 μΩ, the C303 minimizes thermal losses and cuts energy costs by up to 25% in continuous operation. The contactor is available with three optimized magnetic drives — EcoSave with integrated PWM for low holding power, High Efficiency Drive (HED) for maximum coil efficiency, and Precharge for safe inrush current limiting, making it adaptable to a wide range of applications. Safety is reinforced by a mirror contact auxiliary switch (IEC 60947-4-1), ensuring reliable feedback in critical control systems. Rated for operation from –40°C to +85°C, with short-circuit withstand capacity up to 5,000 A for 20 ms, the C303 delivers dependable bidirectional switching for EV fast charging, stationary storage, grid stabilization, photovoltaics, and other high-demand DC applications.

“The C303 isn’t just about technical specifications — it’s about giving our customers confidence in the face of massive demand,” said Pusch. “They need solutions that can scale, run reliably in all conditions, and reduce total operating costs over the long term. That’s what makes the C303 different: it allows system builders to focus on growth and innovation instead of worrying about the limits of their switching technology.”

The C303 series is part of Schaltbau’s Eddicy brand, dedicated to empowering efficient and secure electrification for future-oriented DC applications across diverse industries.

As part of a broader production portfolio, it reflects Schaltbau’s ability to scale and adapt solutions in line with evolving customer requirements. 

Find detailed information about the C303 series or inquiries on availability here.

In fact, V2G sits at the intersection of two converging challenges: first, the accelerated electrification of transportation which increases electricity demand considerably, and second, the growing pressure on energy grids to integrate renewable energy sources and to manage demand peaks.

What if cars were part of the solution, not the problem

On average, private cars in industrialized countries are driven approximately one hour per day only, leaving them parked for about 95% of the time. V2G plans to turn this idle time into an advantage by using EV’s on-board battery modules as buffer storage. From this storage, they can feed electricity back into the grid in times of peak demand. Once rolled out broadly, EVs would not just consume power, but would contribute to grid stability (by reducing the probability of disruption from load variations), to more renewable integration, energy storage and resilience. In addition to grid operators, vehicle owners would also benefit by charging their EVs at off-peak times and selling electricity back to the grid at peak times when prices are higher.

Vehicle-to-home (V2H) or vehicle-to-building (V2B) are concepts in which the vehicle, photovoltaic panels on the roof, and the building are connected and in which the EV fulfills the role of electricity storage for the household: EVs can generally store more than an average home’s daily energy demand.

V2G: Plenty of potential for electrification, grid stability and energy storage …

In early 2025, the National Development and Reform Commission in China and the Chinese energy authority have announced the launch of 30 V2G pilot projects in nine cities, highlighting the potential of EVs for energy storage in real life conditions. In Europe, the Fraunhofer Institutes ISI and ISE for Transport & Environment claim that EVs could emerge as “batteries on wheels” and “virtual power plants” which have the “potential to revolutionize our energy system”. According to their study, bidirectional charging could save EU energy systems EUR 22bn by 2040 due to a reduction of generation capacity, curtailments and fuel consumption. Total savings between 2030 and 2040 could amount to EUR 175.45bn, which almost equals the entire EU budget in 2023.[2]

As a result, EVs could contribute more than 4% of Europe’s electricity demand by 2030 (equaling the energy supply of 30 million households), more than 10% by 2040[3] and could enable an additional 430 gigawatt of solar power capacity, nearly doubling the current EU capacity. The need for stationary battery storage could be cut by a whopping 92% in 2040, while backup power plant capacity could also be reduced significantly.[4]

... yet significant challenges persist

While the potential of V2G is big, so are the regulatory, legal, liability and technical challenges related to it. First off, it needs a high number of electric vehicles with bidirectional charging as well as public and private connection points to the grid. Secondly, obstacles such as lack of standardization and interoperability, with different communication protocols and inverter specifications, need to be overcome. In addition and as of yet, there are insufficient grid incentives and compensation models for grid operators and EV owners.

V2G is also considered particularly challenging since the vehicle owner would leave central control functions of the charging and discharging to the grid operator. This would affect the manufacturer’s warranty conditions, further aggregating battery degradation concerns. Since rechargeable batteries have a finite number of charging and discharging cycles – could V2G lead to accelerated battery wear and less value? That challenge is to be addressed by the joint teams of battery manufacturers, OEMs, grid operators and government.

Even though EU legislation is supporting bi-directional charging with the Alternative Fuels Infrastructure Regulation (AFIR) and updates to the Renewable Energy Directive (RED II/III), which includes mandates for interoperability and smart charging capability, and more bidirectional-capable vehicles are entering the market (in accordance to ISO15118-20), full-scale implementation is pending.

V2G-ready contactors: Engineering challenges in bidirectional power systems

V2G challenges, however, do not stop at the regulatory level but also extend to the system components of both EVs and charging stations. Firstly, DC safety and isolation requirements are very strict. V2G-ready contactors must be engineered for symmetrical arc handling and consistent performance regardless of current direction. Isolation must be maintained under all fault conditions, including routine switchings and overcurrent conditions. One of the coming trends is integration with control and monitoring systems at the vehicle and charging station, so smart contactors become particularly valuable.

Secondly, round-trip efficiency, the efficiency of the entire charging and discharging cycle, is estimated between 80 and 90%, depending on factors such as battery health, temperature, charge rate and charge state but also on system components other than the battery. These losses, however, are crucial for evaluating the economic viability of vehicle-to-grid.[5] Advanced bi-directional contactors such as Schaltbau’s C303, C305 and C330, C310 and C320, feature silver alloy contact pills of the right size and the proper contact force which significantly reduce contact warming (measuring 2 to 3 times lower than competitors). Because of their superior thermal management capabilities, they reduce heat dissipation, hence protecting components from excessive wear and maintaining an efficient energy transfer.

They also feature a compact, open-isolation concept which prevents rupture even under the heaviest failure conditions and heavy short-circuit events. Schaltbau contactors with an integrated mirror contact function for switch-state monitoring also ensure a high standard of safety for the entire system.

EVs: More than decarbonization of transport

Electric vehicles show the transport sector a clear way to decarbonization, but there are certainly more benefits to be realized if the regulatory, policy and technical challenges of V2G are mastered. As a solution provider for advanced bidirectional charging challenges, Schaltbau’s advanced contactors contribute to system-level system and reliability in complex bidirectional environments.

[1] Statista, Global energy storage - statistics & facts, February 27, 2025.

[2] Fraunhofer ISE & Fraunhofer ISI on behalf of Transport & Environment, Batteries on wheels: the untapped potential of EVs, Oct 30, 2024.

[3] EY & Eurelectric, Plugging into potential: unleashing the untapped flexibility of EVs, 2025.

[4] Fraunhofer ISE & Fraunhofer ISI on behalf of Transport & Environment, Batteries on wheels: the untapped potential of EVs, Oct 30, 2024.

[5] Joint Research Centre of the European Commission Technical Report, Vehicle-to-Grid and/or Vehicle-to-Home Round-Trip Efficiency, 2021.

When Warren Buffett stated, "Price is what you pay, value is what you get," he could have been speaking directly to today's engineering and procurement experts tasked with selecting critical electromechanical components for industrial, energy storage and e-mobility applications. Their challenge is to decide based on cost, quality, service life and sustainability, all at the same time.

Without doubt, ESG requirements have tightened, and global warming is advancing faster than we previously imagined. However, cost pressure, customer expectations, competition, and a host of macroeconomic challenges are also intensifying, making it harder to secure long-term success. So how do you decide?

Clearly, for the transition to a climate-neutral economy to occur, clean technology needs to have a lower total cost of ownership (TCO) to stand a chance of being adopted over traditional components. Battery and solar technology are a case in point where dwindling prices allow business decisions that are fully aligned with environmental targets.

Total cost of ownership in electrical component selection

In industrial automation and electrification, total cost of ownership has become an essential metric because it calculates not only the purchase price but all costs until the end of an electrical component’s lifetime. This includes operating costs, set-up and ongoing maintenance costs, service-life before replacement and more.

This more holistic approach transforms component selection from a narrow financial calculation into a strategic decision. Indeed, according to research from Deloitte, procurement leaders named “addressing total lifecycle/ownership costs” to be among their top five strategies to deliver value to their respective enterprises.[1] At the same time, procurement departments are often stretched thin: Calculating each single cost component in a TCO analysis may be unrealistic and overdone.

The hidden cost of energy losses

Inefficiencies in electromechanical components are a challenge in energy, e-mobility and industrial systems. Seemingly modest components controlling the power flow, such as contactors, can have very different effects on operational costs. Schaltbau and Eddicy customers and their (end) customers buy, store and/or sell energy via their applications – be it electric vehicles, charging stations, energy storage solutions or test benches – obviously, they don’t want to lose it.

How can a contactor contribute to energy efficiency? Resistance is the parameter where energy loss within the contactor can occur and which can be affected. To do this, contactors need to optimize their coil consumption and to keep their contact resistance as low as possible. Schaltbau’s Eddicy contactors provide best-in-class efficiency because of their massive AgSno2 contact tips (versus pure copper or thin-film plated contact tips) and electronic control for the optimal power consumption both at pull in and holding. As a result, contact warming is two- to three times lower than comparison competitors.

Less energy loss in the coil circuit and at the contact tips translates into reduced (energy) costs, better ranges and optimized thermal management/cooling for e-vehicles and e-charging, and lower total operational costs for energy storage systems. While some applications may only need two contactors, most charging stations require at least a half dozen. And energy storage systems easily contain dozens or hundreds of contactors which are in operation 24/7. Even small differences in energy efficiency can add up quickly.

TCO calculator: Show don’t tell

Eddicy’s direct current (DC) contactors have a unique selling point: As their coil consumption and power losses are much lower compared to competition, the (end) customer will save energy and costs in their system over the full product lifecycle. This benefit is not just a promise, but a proven result.

Schaltbau’s TCO calculator compares the total cost of contactor power loss for your entire application using Schaltbau contactors vs. competitor products. The calculation inputs the respective contactors’ voltages (V), thermal current (A), contact resistance (mΩ) and coil power loss (W). It then calculates the power loss per pole, namely, the energy loss via contact resistance and coil consumption, the total energy loss (kWh/year) as well as the total cost of contactor power loss for the entire system. The calculation can be adjusted to the respective energy price a customer pays, the number of contactors to be installed in their systems, the number of hours per day the system is running and the expected contactor lifetime before replacement.

Electric charging station power loss calculation

Indeed, minimizing power losses in your contactor add up quickly (s. Figure 1): A charging station, for instance, which deploys 6 contactors (two contactors per gun and two contactors for the switching matrix), will lose about EUR 1,014 in contactor power losses for the charging station over 15 years of operation with the C303 Ecosave, but a whopping EUR 2,759 or EUR 2,171 with competitor contactors, respectively.
 

Energy storage system power loss calculation

The cost difference widens significantly in higher current applications that run 24/7, such as energy storage systems (s. Figure 2). In a large system with 20 contactors, the total contactor power loss for the entire system over 15 years of operation is EUR 9,853 with an Eddicy C310 contactor but rakes up to EUR 22,069 and EUR 17,370 with competitor contactors. Hence, making a purchase decision based purely on the price of the component might lead to unnecessarily high operational costs down the road.

Energy efficiency: “First fuel” for the energy transition

As the International Energy Agency points out, energy efficiency is the “first fuel” in the energy transition as it provides some of the quickest and most cost-effective CO2 mitigation options while lowering one’s energy bill. By accounting for energy efficiency, operational reliability, and service longevity, TCO helps to illuminate how premium components deliver twin imperatives: substantial cost savings over the product lifecycle and advancing sustainability objectives. For this reason, economic optimization and sustainability become complementary forces rather than competing priorities in the journey toward electrification and decarbonization.

Interested in your personalized contactor TCO analysis? Download our TCO calculator here to see the potential savings in your application – or reach out for a personalized analysis from our experts.
 

[1] Deloitte, 2023 Global Chief Procurement Officer (CPO) Survey. Orchestrators of Value, p.8.

“Megawatt charging represents a milestone in commercial e-mobility. By reducing charging time to the length of a driver’s break, it significantly maximizes both flexibility and efficiency off green transportation,” said Helmut Pusch, CEO of Schaltbau GmbH Group. “With our new contactors, we are delivering the future of charging today, emphasizing our commitment to driving electrification for a sustainable future.”

The new contactors C305 and C805 support the current Megawatt Charging Standard (MCS) level 2 of 1,500A, the C330 and C830 contactors are 3,000A bi-directional contactors designed to enable MCS level 3 high-power DC charging. All four products feature a compact, open-isolation concept which prevents rupture even under the heaviest failure conditions and heavy short-circuit currents, preventing damage to surrounding components. The contactors can withstand a short-time current of up to 15,000A for five milliseconds without the contacts welding, significantly enhancing system safety. With separate contact systems for switching and current carrying, the series stands out for its exceptional longevity.

Furthermore, silver alloy contact pills result in a contact resistance as low as 40 µOhm, ensuring best-in-class performance with low contact warming. An integrated economizer ensures optimal pull-in performance during switch-on and minimizes energy consumption in holding mode. As a result, the megawatt charging contactor series reduces power losses in the system, delivering up to 25% of energy cost savings.

“Power losses grow quadratically with current, so minimizing contact resistance in high-current applications is crucial for maintaining an efficient energy transfer and ensuring competitive total costs of ownership", said Schaltbau CEO Pusch. “That’s why our new Eddicy contactors are ideal for high-current applications like fast charging, as well as other energy and e-mobility applications such as battery storage systems and test benches.”

The C805 and C830 contactors for mobile applications will be unveiled today at the ACT Expo in Anaheim, California. The C305 and C330 contactors will be debuted at smarter E Europe in Germany where the C330 has already been nominated for the smarter E AWARD, which honors companies shaping the future of energy and mobility.

Learn more about C305/C805 & C330/830 contactors here

From an early age, we learn the importance of making informed decisions, whether as private consumers or when making B2B decisions in our professional lives. Whether we prefer customer testimonials, independent test research, certification or product reviews, we all want to be sure that what we see is what we get.

Suppliers are responsible (and liable) for their products. Particularly in industries where failures can have severe consequences, the rigorous testing of products is not only a technical necessity but a legal requirement to ensure compliance with safety and quality regulations.

The global push for electrification and the increase in moving and stationary battery systems is transforming entire industries, from automotive to energy and industrial automation. As companies innovate and develop new electrified solutions, rigorous testing both in development test benches and end-of-line testing becomes critical in ensuring performance, safety, reliability and regulatory compliance.

The role of test benches in electrification

High voltages, high frequencies, thermal management under challenging current profiles, and possible failure behavior evaluation – all part of the unique engineering challenges electrification introduces – necessitate precise validation and testing of electrical components, power electronics, and entire systems under real-world conditions before deployment. Hence, engineers require adaptable, modular set-ups capable of handling increasing power levels: With electric vehicles and grid storage systems operating at voltages up to 1,500V and above and currents in the kiloampere range, test benches must handle extreme conditions safely.

Test benches, systems to test the function and defined parameters of a device under test (DUT), require powerful contactors and relays to connect the different measurement instruments, power supplies and loads as well as to switch-off of the complete system in case of an emergency. For e-mobility, battery and many other energy applications, the challenge lies in safe extinguishing of the arc, insulation breakdown, and reliably withstanding thermal currents and short circuit currents during high-power testing.

What makes a test bench contactor different?

So, why would your everyday contactor not do it in a test bench to ensure safe power handling? Because they need to follow extraordinary safety standards and have a number of special requirements. Firstly, test equipment needs to be very robust since it is typically difficult to maintain. Understandably, customers prefer electromechanical components that they install once and then never have to think about again.  High short-circuit withstand capacity to avoid “stuck-on” contactors with welded contacts is mandatory as well as a mirror contact feedback according to IEC 60947-4-1. Contactors should be ready to serve a wide current range as well as voltages sometimes than it’s typical in “classic” industry applications. And, above all, test bench contactors need to ensure reliable control of the test samples as well as the safety of the operating personnel and the long-term availability of the test system itself in the event of a fault.

Schaltbau customers rely on our wide range of contactors for a variety of energy and e-mobility applications. Key features of those contactors include their very low contact resistance, leading to low heat dissipation and high thermal currents, excellent isolation voltage up to 4,800 V as well as auxiliary contacts with normally-open and normally-closed functionality or mirror contacts functionality for a safe feedback loop according to IEC 60947-4-1, Annex F. In addition, their high bi-directional current interruption capability makes them particularly suited to evaluate both charging and discharging cycles or energy simulations with connection to a grid. Their non-encapsulated arc chambers provide for a robust design, their sturdy contact-tips makes the probability of the contacts welding low.

Safe and reliable switching for test benches with Eddicy

Our portfolio of Eddicy contactors is designed to deliver exceptional performance and safety across a wide range of applications in e-mobility and energy testing. With a variety of series, such as the CP, 320, 310, 300, C303 and more, we provide versatile solutions to meet both standard and highly specialized requirements.

From high currents to high voltages, our contactors are engineered to handle everything from 10 to 2000A and 24V to 3000V, covering both AC and DC loads. Each series is built with robust features to ensure long-lasting reliability, high efficiency, and exceptional performance even under the most demanding conditions. Our products can be customized to fit any need, whether it's for specialized testing, custom solutions for extra-high voltages, or even addressing unique safety and mechanical challenges. No request is too complex or "off-the-wall" for us.

Learn more about our solutions and how we can support your electrification goals here.

"For decades, Schaltbau contactors have powered some of the world’s most demanding rail applications," said Steffen Munz, CEO of Schaltbau GmbH Group. “Today, that same field-proven technology is driving innovation in high-power industries like mining, construction, and test benches—setting new benchmarks for safety, efficiency, and durability in every connection.”

From energy conversion and storage to test benches and off-road e-mobility, CP and CF contactors are designed to handle voltages and currents with precision and reliability. With up to 25% energy cost savings due to low contact resistance and reduced contact heating, these high-power contactors offer full bidirectionality thanks to their specially designed arc-extinguishing chamber.

The expanded CP series includes three new variants—rated at 800A, 1000A, and 1500A— engineered to perform seamlessly under heavy load conditions, even in high-vibration, high-contamination settings. The arc-handling is done exclusively by permanent-magnetic blowout. This patented technology ensures fully bi-directional breaking capability and a more compact design, reducing dimensions, weight and required space. Additionally, the series also includes the Smart-CP contactor, a next-generation intelligent switching device prototype. Equipped with integrated sensors, real-time monitoring, and self-diagnostic capabilities, it will bring intelligence into critical power applications, improving energy management and reducing downtime.

 The CF series offers a modular approach with contactors available with up to 6 main contacts in both NO (normally open) and NC (normally closed) configurations, handling currents up to 400A and voltages up to 3000V. The CF series can switch both alternate current (AC) and direct current.

Eddicy products are designed to unlock the full potential of electrification for a more sustainable, carbon-free future as they reliably switch, connect, control, and protect DC applications in energy and e-mobility such as charging stations, energy storage systems, and electric vehicles of all kinds. DC applications and products that switch, protect, and secure high-voltage power play a crucial role in the transformation to a climate-neutral economy. 

Technical details:

 CP series: 

• Current range: 600A to 2000A, with the three new versions rated at 800A, 1000A, and 1500A. 
• Voltage range: Nominal voltages of 1.5kV to 3V, suitable for both AC and DC loads. 
• Mechanical life: Over 1 million switching cycles for NO and NC contacts, making them highly durable in harsh operating conditions. 
• Configuration flexibility: The CP contactors feature 3 arc chamber types (A, B, D) and come with a monostable or bistable drive system, ensuring broad applicability and easy customization for e-mobility and energy applications. 

 CF series: 

• Current ratings: Available in 200A, 300A, and now 400A models, providing a scalable solution for different power needs. 
• Switching chambers: Each variant is built with up to six poles (for 200A/300A models) or four poles (for the 400A model), with fully bi-directional switching for both AC and DC loads. 
• Mechanical life: With over 1 million cycles, the CF series delivers longevity, reducing the need for frequent maintenance. 
• Operational flexibility: The modular design supports up to four auxiliary contacts (S870 or S826), enhancing its applicability across a variety of operational conditions. 
• Critical current resilience: The CF series is engineered to handle high short-circuit withstand currents of 4kA without critical current range issues. 

Governments, industries, and consumers are increasingly adopting renewable energy sources such as wind and solar. However, the intermittent nature of these sources, where energy generation fluctuates based on weather conditions, presents significant challenges for grid operators. ESS help mitigate these challenges by storing excess energy generated during peak production and releasing it when demand outpaces supply. As demand increases, ESS are becoming integral to energy management. But with this growth comes the need for systems capable of handling larger energy capacities, scaling effectively, and ensuring safety during operation—requirements that demand the highest standards of performance and reliability from every ESS component, including the contactor.

Contactor Technology: Essential to ESS Operation 

Contactor technology is critical in ESS and contribute to overall safety and efficiency in many ways. They manage the flow of power between the grid and storage units by connecting and disconnecting strings and inverters as needed. In the OFF position, the contactor ensures safety by reliably galvanic isolating high-voltage circuits. This prevents electrical hazards to personnel and protects equipment from damage. In the ON position with extremely low ohmic resistance, the contactor efficiently handles high currents, ensuring smooth and reliable operation. In addition to these tasks, contactors provide fault protection by isolating faulty components during overcurrent, preventing damage and maintaining system safety. 

To ensure long-term reliability, modern contactors are built with durability in mind. They use high-performing materials like silver-tin-oxide alloys to avoid contact-welding under system failure conditions and improve the Mean Time Between Failures (MTBF), minimizing downtime and maintenance while optimizing ESS performance. 

Modern contactors are engineered to meet the increasing demands of energy storage systems. Below are the key features that ensure optimal performance and reliability in high-power applications:

1. High Current and Voltage Capacity

Modern contactors are designed to handle substantial current and voltage loads, making them crucial for large-scale ESS applications. The C303 contactor, for example, is tailored for high-performance ESS, managing DC power with a maximum switching voltage of 1500V and continuous current handling up to 500A or more under certain conditions. Its bi-directional switching capability ensures reliable operation during both charging and discharging cycles. To withstand these conditions, contactors must have high interrupting capacities to manage overcurrent without failure. Arc-resistant silver alloy contacts and robust construction further enhance durability and performance in demanding high-power environments.

2. Thermal Management and Contact Materials

Efficient thermal management is critical for preventing overheating in high-power applications, where high currents generate significant heat. Contact materials such as silver-tin-oxide offer high thermal conductivity and resistance to oxidation, ensuring reliable performance over time. The C303, for example, uses arc-resistant silver-tin-oxide alloys to minimize contact resistance and reduce heat generation, maintaining long-term reliability.

3. Compact and Space-Efficient Design

As ESS installations become more compact, modern contactors are designed to maximize space efficiency. The C303 contactor features a compact form factor, allowing it to fit into smaller enclosures without compromising performance or safety. This space-efficient design makes it ideal for applications where space is at a premium. Its ability to integrate seamlessly into high-density energy storage systems further underscores its versatility. 

By combining high current capacity, efficient thermal management, reliable switching, robust open-air design, and a compact design, modern contactors like the C303 offer reliable, cost-effective solutions for the evolving needs of ESS. These features are essential for minimizing downtime, reducing energy losses, and ensuring long-term system efficiency. The extended service life, low maintenance requirements, and high performance make modern contactors a critical component for achieving optimal performance and long-term reliability in ESS.

The Future of Contactor Technology in ESS 

The future of ESS will be shaped by ongoing innovations in contactor technology. Advancements in design, materials, and integration with emerging technologies—such as sensor integration and communication—will enable contactors to handle higher power capacities, improve thermal management, and increase energy efficiency. These developments will ensure that ESS remain sustainable and capable of meeting the demands of a renewable-powered future. 

Modern contactors already provide features like high current capacity, reliable switching, and exceptional durability. As ESS continue to grow in importance, selecting advanced contactor technology will be critical for maximizing efficiency, reliability, and long-term safety in energy systems. Additionally, AI and sensing technologies are enabling predictive maintenance and smart energy management, which will enhance the performance of ESS by proactively addressing issues before they lead to failure. 

Schaltbau, a global specialist in direct current (DC) applications, is successfully expanding the footprint of its Eddicy brand in Turkey by introducing its C303 DC contactor to the Turkish energy and e-mobility markets at the upcoming EVCharge Show in Istanbul. 

Engineered for bidirectional DC applications, the C303 series offers unmatched performance suitable for a range of industries including stationary charging infrastructure, battery test benches, non-IATF electric vehicles, DC microgrids, and more. With ultra-low contact resistance just above 100 µΩ, power loss is minimized, optimizing system efficiency; and with reduced contact warming, measuring 2 to 3 times lower than competitors, the series boasts superior thermal management capabilities. This translates to enhanced reliability and longevity, even in challenging conditions, thanks to optimized contact forces and advanced contact pills. 

"With our ambition to be on the forefront of the electrification, we are proud to support Turkey’s transition to a cleaner transportation ecosystem by close cooperations with key customers in applications such as e-busses, battery packs or charging," said Luigi Cristiano, Director Sales Segment Energy. "At EVCharge Show from November 13-15 we look forward to showcasing our Eddicy portfolio at our booth in Hall 1, as well as its impact within the application at our partners’ stands. Amongst others, YED Teknoloji and ORGE are presenting the C303 contactor inside the power distribution units of their newest DC charging stations.” 

Driven by the growing adoption of electric vehicles and government initiatives to promote green transportation, Turkey’s EV charging market is expected to grow by almost 15% annually until the end of the decade and has been surpassing the number of 10,000 EV charging stations this year. 
 

About Eddicy

As pioneers of electrification, Schaltbau has been championing safety on rail for generations. Building on this experience, with our new brand Eddicy we also create future-oriented products and solutions with the highest standards of safety and reliability to switch and protect DC applications in energy and e-mobility.

• Safe disconnection of the battery unit: Schaltbau contactors can handle high-voltage arcs that can occur when switching DC loads. In case of maintenance or an emergency shutdown, they ensure a safe disconnection of the battery unit from the inverter in energy storage systems. 
• Increased system efficiency: Due to their low contact resistance and low energy consumption, they contribute to overall efficiency of the energy transfer to and from the battery and minimize heat dissipation: to transfer the energy and not to lose it. 
• Full bi-directionality: Schaltbau’s DC contactors ensure the safe disconnection of high power regardless of the current direction. They safely manage potential fault modes in both directions of current flow. 
• High breaking capacity: DC contactors meet the high requirements for breaking capacity of industrial storage systems, leading to increased system availability and improved total cost of ownership (making capacity, continuous thermal current, rated short-time withstand current). 

The global energy storage market is projected to grow rapidly – at a compound annual growth rate (CAGR) of around 10% within this decade. Apart from the obvious environmental advantages of integrating a higher share of renewables, there are also fundamental economic benefits for enterprises wanting to integrate renewable energy generation and on-site storage systems. 

Energy storage is a smart move for business, not just the environment 

Electricity purchase prices are calculated according to a formula that includes the peak loads drawn and the provision of sufficient capacity. These provision charges must be paid for the entire billing period, even though the peak load capacity might only be used for a fraction of the time. Energy storage enables energy to be saved for later use. Consequently, it allows businesses to avoid higher tariff charges, reduce operational costs and save on their electricity bills. 

In addition, energy storage solutions supply energy continuously even when the network is unstable due to peaks or extreme weather events, thus reducing grid dependency. Energy storage facilities also provide back-up power in the event of an outage guaranteeing business continuity. 

Energy storage will be crucial for the world to accelerate its journey towards net zero. Sophisticated industrial components, such as DC contactors, connect renewable energy sources, energy storage systems and electrical consumers without the energy losses that occur when direct current is converted to alternate current. In the quest for carbon-neutrality, the paradigm shifts toward renewable energy generation and advanced energy storage systems, creating the energy solutions for a better tomorrow – and Schaltbau is there every step of the way. 
 

Read more about Schaltbau contactors and Eddicy energy storage solutions here. 
 

References:

1. International Energy Agency. (2021). Net zero by 2050: A roadmap for the global energy sector. International Energy Agency.
2. Statista. (n.d.). Energy storage. Retrieved June 12, 2024, from https://www.statista.com/topics/4632/energy-storage/#topicOverview
3. European Commission. (n.d.). Recommendations on energy storage. Retrieved June 12, 2024, from https://energy.ec.europa.eu/topics/research-and-technology/energy-storage/recommendations-energy-storage_en

• Fully bidirectional, meeting key operational (KO) criteria for applications such as energy storage, charging stations, electric vehicles, and vehicle-to-grid (V2G) 
• Very low contact resistance of slightly over 100 µΩ, best-in-class performance with low contact warming and low power loss due to optimized contact pills 
• Properly designed coil drive with fast switch on and AgSnO2 contact tips result in superior performance in short time currents (5kA capacity for 20 milliseconds without contact welding) and high making capacity (currents up to 2kA without contact welding) 
• High diagnostic coverage and performance for security calculations due to NC aux contact with mirror contact function compliant with EN6047-4-1 Annex F 
• Smallest Schaltbau contactor for 350A Thermal current, complete plug-and-play capability 

“Through meticulous engineering and a tireless pursuit of excellence, the C303 series exemplifies our commitment to delivering cutting-edge solutions,” said Steffen Munz, CEO, Schaltbau Group. “This contactor series sets new standards for performance and efficiency in bidirectional DC applications. We are proud to introduce a product series that not only pushes the boundaries of innovation but also empowers our customers to achieve their electrification goals with confidence.” 

With ultra-low contact resistance just above 100 µΩ, power loss is minimized, optimizing system efficiency; and with reduced contact warming, measuring 2 to 3 times lower than competitors, the series boasts superior thermal management capabilities. This translates to enhanced reliability and longevity, even in challenging conditions, thanks to optimized contact forces and advanced contact pills. 

Designed for high inrush currents or capacitances, C303 contactors have a making capacity of 2,000 amps. Continuously carrying up to 350 amps, they withstand short-circuit currents of up to 4,000 amperes for 20 milliseconds, staying fully functional with no contact welding – setting new standards for functionality in short time currents. Full bidirectionality ensures seamless disconnection of high-output circuits, up to 1,200 amps/850 volts, regardless of current direction. 
 

The well-designed coil drive ensures rapid switch-on times, enhancing system responsiveness and efficiency. Additionally, the use of AgSnO2 contact tips minimizes fire or explosion risks, ensuring operational safety. Finally, offering versatile auxiliary contact options—NC, NO, and CO—the C303 series is compatible with various system configurations. High diagnostic coverage and compliance with EN6047-4-1 Annex F ensure exceptional performance levels for security calculations. 
 

As part of Schaltbau’s new brand Eddicy, the C303 contactor series provides unparalleled performance and reassurance in critical applications. 

“Schaltbau has always been synonymous with innovation, high-quality and reliability,” says CEO Steffen Munz, CEO, Schaltbau. “The launch of Eddicy is the latest testament that we are not just adapting to change. We are driving it. Leveraging our expertise in railway applications, we are transforming ourselves into a technology leader for DC power in the energy and e-mobility sectors as well. This marks a pivotal moment in our history, as we continue to innovate and set the benchmark for excellence in our industry.” 

Eddicy products are designed to unlock the full potential of electrification for a more sustainable, carbon-free future as they reliable switch, connect, control, and protect DC applications in energy and e-mobility such as charging stations, energy storage systems, and electric vehicles of all kinds. DC applications and products that switch, protect, and secure high-voltage power play a crucial role in the transformation to a climate-neutral economy.

The launch of Eddicy is part of a broader corporate brand refresh at Schaltbau that includes modernized logos, a redesigned website, and newly defined corporate mission, vision and values that reflect the strategic focus of the organization. 

The brand update reflects the commitment to deliver pioneering solutions that help electrify the world. It also underscores the company’s drive to further strengthen its core business as a trusted supplier in the global rail market which Schaltbau will continue serving together with its sub-brand SPII.

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