AC Contactor Solutions for the New Energy (Photovoltaic/Wind Power) Sector

 I. Industry Application Challenges​
In new energy applications such as photovoltaic (PV) power generation and wind power generation, AC contactors serve as critical control and protection components. Their operating environment differs significantly from traditional industrial scenarios, presenting two core challenges:

1. ​High Voltage and DC Component:
• The DC-side voltage of PV systems can reach 1,000V or even 1,500V, with fault currents being pure DC. Wind power systems also exhibit rich harmonics, leading to significant DC components in the current.
• DC currents lack natural zero-crossing points, making arc extinguishing extremely difficult. This often results in contact erosion, reduced lifespan, or even equipment failure.
2. ​Harsh Operating Conditions:
• Power stations are typically built outdoors and face extreme temperatures, high humidity, salt spray corrosion (coastal/wind farms), and other challenges. These conditions demand exceptional environmental adaptability and reliability from contactors.

​II. Core Solutions​
To address these challenges, our company has launched a series of AC contactors specifically designed for new energy applications. The core solutions include:

1. ​Dedicated DC Arc Extinguishing Technology — Addressing the Need for High Voltage and DC Component Resistance​
• ​Technical Principle: Employing a specially designed DC arc extinguishing chamber, optimized arc chute materials, shape, and layout to generate a strong electromagnetic field. This effectively stretches and cuts the DC arc, enabling rapid cooling and extinguishing.
• ​Performance: This technology ensures safe, arc-free breaking of PV DC currents at 1,000V or higher voltages, fundamentally preventing increased contact resistance and equipment damage caused by arc erosion. It significantly enhances electrical lifespan and system safety.
2. ​Smart Anti-Backflow Protection — Enhancing System Safety​
• ​Technical Principle: Equipped with an built-in intelligent control unit that collaborates with inverters to monitor current direction in real time.
• ​Performance: When abnormal reverse current (e.g., grid-side fault feedback) is detected, the circuit is cut off within 0.1 seconds. This effectively protects core equipment such as inverters and PV modules from reverse power impact, ensuring grid and power station safety.
3. ​Excellent Wide-Temperature and Protection Design — Ensuring Reliable Operation​
• ​Technical Principle: Key components utilize special engineering materials and environmentally friendly coating processes. Coils and insulating materials are treated with specialized formulations to ensure stable performance under extreme temperatures.
• ​Performance: Capable of operating in a wide temperature range of -40°C to +70°C, with resistance to high humidity, condensation, salt spray, and other corrosive conditions. Fully meets the harsh environmental requirements of outdoor PV power plants and offshore/coastal wind farms, ensuring long-term stable operation.

​III. Application Cases and Value​
​Case: Main Circuit Control Project for a Coastal Wind Farm​

• ​Challenge: The wind farm experienced high salt spray concentration in the air, causing severe corrosion of standard contactors. Contact oxidation led to overheating due to increased resistance, and the high harmonic content in wind turbine currents reduced the lifespan of contactors to less than one year, resulting in high maintenance costs.
• ​Solution: Our dedicated new energy AC contactors were deployed, leveraging their superior salt spray corrosion resistance and DC component handling capabilities.
• ​Results: After replacement, the contactors' service life increased by more than three times under the same harsh conditions. This significantly reduced downtime for maintenance and spare part replacement costs, delivering substantial economic benefits and enhanced safety for the customer.