New Energy Power Electrical protection box assembly 3791010-TZ5F0

As the "safety core" of the NEV’s high-voltage system, the 3791010-TZ5F0 assembly delivers comprehensive, real-time protection against electrical hazards to safeguard the vehicle, occupants, and maintenance personnel. It executes five critical safety functions: 1) Overcurrent & Short-Circuit Protection: Integrated HV fuses (rated 150A–600A) with 10kA–50kA breaking capacity rapidly interrupt excessive current, preventing component burnout or thermal runaway; 2) High-Voltage Isolation: The box’s insulated housing and internal partitions provide ≥3000V AC insulation resistance (per IEC 60664), isolating HV circuits from low-voltage systems (12V/24V) and the vehicle chassis; 3) HVIL Monitoring: Built-in HVIL circuits detect unauthorized box access (e.g., during maintenance) and trigger the VCU to disconnect the HV battery within 80ms, eliminating shock risks; 4) Pre-Charge Protection: A precision pre-charge resistor limits inrush current (≤50A) when the HV system activates, protecting inverter capacitors from damage; 5) Over-Temperature Protection: An internal NTC sensor monitors ambient temperature, alerting the VCU if temperatures exceed 110°C to prevent insulation degradation. These features collectively comply with ISO 6469 and GB/T 18384, minimizing electrical accident risks

The 3791010-TZ5F0 electrical protection box features a NEV-optimized durable structure designed to withstand extreme under-vehicle conditions and high-voltage system stresses. The outer housing is constructed from glass-fiber reinforced PPS (Polyphenylene Sulfide) with a UL94 V-0 flame-retardant rating, offering resistance to high temperatures (operating range: -40°C to 130°C) and chemical corrosion from road salt, coolants, and oils. Internal busbars and terminals use high-conductivity oxygen-free copper (T2 grade) with tin-nickel plating, ensuring low electrical resistance (≤3mΩ) and long-term anti-oxidation performance. The box’s sealing system employs EPDM (Ethylene Propylene Diene Monomer) gaskets with an IP6K9K waterproof/dustproof rating, protecting internal components from high-pressure water jets (e.g., vehicle washing) and dust intrusion. Additionally, anti-vibration rubber mounts absorb up to 25G peak acceleration (per ISO 16750-3), preventing component loosening during rough road operation or heavy-load driving

The 3791010-TZ5F0 is calibrated with NEV-specific technical parameters to match the power needs of modern high-performance NEVs. Its maximum rated voltage is 1000V DC, compatible with 800V ultra-fast charging platforms, and it supports continuous current handling of 300A–600A (matching 200kW–400kW drive motor outputs). The HVIL circuit operates on the vehicle’s 12V low-voltage system with a signal response time of ≤40ms, ensuring rapid HV disconnection in emergencies. The pre-charge resistor (5Ω–10Ω) completes the pre-charge process in ≤2 seconds, optimizing system activation efficiency. Cable entry ports accommodate 25mm²–150mm² HV cables with compression-type glands, ensuring secure, low-resistance connections. Additionally, the box’s weight (≤5kg) and compact dimensions (customized to OE space constraints) enable flexible mounting in underbody or engine bay locations without compromising vehicle weight distribution

The 3791010-TZ5F0 electrical protection box assembly meets strict global NEV safety and quality standards to ensure reliability in critical high-voltage applications. It is manufactured in accordance with ISO/TS 16949 (automotive quality management system) and complies with key NEV standards: IEC 60664 (HV insulation coordination), ISO 6469-3 (EV electrical safety), CISPR 25 (electromagnetic compatibility), and GB/T 18384.3 (Chinese EV safety requirements). Each unit undergoes 100% factory testing, including: 1) Electrical safety testing (insulation resistance, dielectric strength, HVIL function validation); 2) Environmental testing (temperature cycling, salt spray, vibration, humidity); 3) Durability testing (10,000+ HV connector mating cycles, 15-year lifespan simulation); 4) Flame resistance testing (UL94 V-0 verification). To support NEV manufacturers and repair facilities, the assembly comes with a 36-month/120,000km warranty and dedicated technical support—including HVIL troubleshooting, high-voltage safety training, and compliance guidance for maintenance protocols