Download our 2025 Product Catalog for detailed drawings and technical parameters of all switchgear components.
Get Catalog Download our 2025 Product Catalog for detailed drawings and technical parameters of all switchgear components.
Get Catalog
Vacuum Contactor manufacturing is a specialized field within electrical engineering focused on producing high-endurance switching devices for frequent operation applications. Unlike circuit breakers, which are designed for rare fault protection, Vacuum Contactors are the workhorses of the industry, engineered to switch motors, transformers, and capacitor banks hundreds of thousands of times. As a premier Vacuum Contactor Manufacturer, XBRELE produces a comprehensive range of Low Voltage (1.14kV) and High Voltage (7.2kV – 40.5kV) units. Our factory integrates advanced electromagnetic drive technology with premium vacuum interrupters, delivering reliable control solutions for mining, metallurgy, and heavy industrial sectors worldwide.
The manufacturing process for vacuum contactors prioritizes mechanical endurance and electrical consistency. While a breaker might operate 10,000 times, a contactor must reliably perform up to 1,000,000 mechanical operations. This demands a different manufacturing approach.
Electromagnetic System Assembly: The core of a contactor is its solenoid drive. XBRELE winds its own high-grade copper coils and assembles the magnetic yoke with precision stamping parts. We utilize a specially designed “Double-Coil” or “PWM Control” circuit to minimize holding power consumption and reduce heat generation during continuous operation.
Vacuum Interrupter Alignment: For the JCZ High Voltage Series, aligning the vacuum interrupter is critical. We use automated fixtures to set the contact gap and over-travel with 0.1mm accuracy. This precision ensures that the three phases close simultaneously, preventing “single-phasing” which can destroy sensitive motors.
Insulation Frame Molding: For our mining and solid-insulated series, we mold the frames using high-strength DMC (Dough Molding Compound) or Epoxy Resin. This robust structure prevents vibration-induced failures, a common requirement for underground mining equipment.
To achieve high switching frequency (up to 1,200 times/hour), the materials used in vacuum contactors must withstand extreme stress. XBRELE selects materials for durability.
The production of high-performance contactors relies on specialized assembly and testing machinery. XBRELE has invested in a fully equipped production line to ensure consistency.
Automatic Winding Machines: To ensure the pull-in and drop-out voltages are consistent across every batch, our solenoid coils are wound on high-speed automatic winding machines with tension control.
Running-In Test Benches: Unlike some suppliers who ship immediately after assembly, XBRELE employs “Mechanical Run-In” benches. Every contactor undergoes 300+ no-load operations to settle the mechanical springs and latches before final calibration.
Vacuum Brazing (Outsourced Control): While we procure vacuum bottles from top-tier specialists, we maintain strict IQC equipment to verify the brazing quality and vacuum integrity of every batch before they enter our assembly line.
Testing procedures for Vacuum Contactors are focused on endurance and reliability under frequent cycling. XBRELE enforces strict quality gates compliant with IEC 60470 and GB/T 14808.
| Test Name | Standard / Limit | Purpose |
|---|---|---|
| Pick-up & Drop-out Voltage | 85% – 110% Us | Ensures the contactor closes reliably even during voltage dips. |
| Power Frequency Withstand | 32kV / 42kV (for 7.2/12kV) | Verifies dielectric strength between open contacts and to ground. |
| Main Circuit Resistance | < 60-80μΩ | Checks for proper contact pressure to prevent overheating. |
| Synchronization Test | < 2ms difference | Ensures all three phases make contact simultaneously. |
| Vacuum Degree Check | Spark Test / Magnetron | Confirms the vacuum bottle has not leaked during assembly. |
For our “Mechanical Latching” models (used where power consumption must be zero during holding), we perform additional latching reliability tests to ensure the device stays closed even under heavy vibration.
Vacuum Contactors are not “plug and play” commodities; they often need to fit into specific legacy motor starters or specialized machinery. A custom manufacturer like XBRELE allows you to tailor the device to your application.
We offer customization in Holding Type. We can manufacture Electrical Holding types (standard) or Mechanical Latching types (which stay closed without power, ideal for unstable grids).
For the mining industry, we customize the CKJ Series (1.14kV) with reinforced frames and special control voltages (e.g., AC 36V, 127V) commonly used in underground electrical systems. We can also adjust the terminal layout to match existing busbar configurations, saving you significant retrofit costs.
Manufacturing contactors requires deep knowledge of “Utilization Categories” (AC-3, AC-4). XBRELE engineers understand that switching a motor (Inductive load) is physically different from switching a capacitor bank (Capacitive load).
Our experience ensures we recommend the right product. For example, for Capacitor Switching applications, we recommend our CKG Series equipped with specialized pre-insertion resistors or high-grade vacuum bottles designed to withstand the high inrush currents and Transient Recovery Voltage (TRV) associated with capacitor banks.
By sourcing directly from XBRELE in China, global OEMs and distributors gain a competitive edge. We manufacture the solenoid drives and insulation frames in-house, bypassing the markup of assemblers who purchase components externally.
Our Low Voltage Vacuum Contactors (1140V) are widely used as cost-effective replacements for expensive air-break contactors in heavy-duty applications. They offer 10x the electrical life at a comparable price point, drastically reducing the Total Cost of Ownership (TCO) for end-users in cement plants, steel mills, and mines.
XBRELE’s production lines are designed for versatility. We produce both standard 3-Pole Contactors (JCZ5) and specialized Single-Pole Contactors (JCZ1) used in electric locomotives and induction heating systems.
Our adaptability extends to installation styles. We offer fixed-type units for standard panels and handcart-type units compatible with KYN28 switchgear, allowing the contactor to be racked in and out just like a circuit breaker. This flexibility makes XBRELE the preferred partner for Panel Builders dealing with diverse project requirements.
Modern vacuum contactors are inherently eco-friendly. Unlike oil or SF6 switches, vacuum technology emits no greenhouse gases and poses no fire risk. XBRELE takes this further by optimizing our control circuits.
Our electronic control modules use Pulse Width Modulation (PWM) or energy-saving coils that reduce holding power by up to 90% compared to traditional AC coils. This not only reduces the carbon footprint of the operation but also lowers the heat load inside the switchgear cabinet, prolonging the life of other components.
China leads the world in vacuum switching technology production volume. XBRELE leverages the mature supply chain in Wenzhou to offer:
When selecting a partner, look beyond the catalog. Consider:
XBRELE provides transparent technical data and full aftermarket support, ensuring your motor control centers run without interruption.
Stop paying trader margins. Connect directly with XBRELE’s engineering team for your Vacuum Contactor needs.
Get a Factory Quote