KILOVAC High Voltage Relays and Contactors Table of Contents High Voltage DC Contactors Quick Reference Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4, 7-5 MAP Aerospace Military Contactors MAP101 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6, 7-7 MAP100 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8, 7-9 MAP200 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10, 7-11 MAP201 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12, 7-13 CAP Aerospace Commercial CAP202 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14, 7-15 CAP200 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16, 7-17 CAP120 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18, 7-19 Higher Power and Sensing Contactors KHR500 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20, 7-21 K1K Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22, 7-23 KCS01 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24, 7-27 KCS03 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28, 7-32 EV OEM/Commercial & Electric Vehicle EV202 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33, 7-34 EV200A Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35, 7-36 EV200B Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37, 7-38 EV200P Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39, 7-40 EV100 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-42 LEV Industrial Commercial LEV100 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 - 7-45 LEV100H Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 - 7-47 LEV200 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48, 7-49 AC Contactors FM200 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50, 7-51 Traditional 270 Vdc Aerospace Contactors AP90X Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52, 7-53 AP150X Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54 AP265X Series, AP265P Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55 AP350X Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56 EV250 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57 - 7-60 EV500 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61, 7-62 PD350X Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63 PAGE 1 KILOVAC High Voltage Relays and Contactors Traditional 28 Vdc to 1800 Vdc Contactors 7 KILOVAC High Voltage Relays and Contactors Table of Contents (Continued) High Voltage Relays Quick Reference Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65, 7-66 270 Vdc Aerospace Relays AP5A Series, AP5B Series, AP5C Series, AP5P Series, AP5R Series. . . . . 7-67 - 7-69 AP10A Series, AP10B Series, AP10P Series, AP11A Series. . . . . . . . . . . . 7-67 - 7-69 AP44P Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70 28 Vdc to 1800 Vdc Relays PD5A Series, PD5B Series, PD5C Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71 PD10A Series, PD10B Series, PD10P Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72 1.5 - 2.0 kV Relay K45C Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73 3.5 kV Relays HC-1 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74 HC-3 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74 HC-5 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74 5.0 kV Relays K41A, K41B Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75 K41C Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75 K41P Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76 K41R Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76 K40P Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77 K40P364 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77 7.5 kV Relays KM-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78 8.0 kV Relays K47A Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79 K47B Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79 HC-2 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80 HC-6 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80 H-18 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81 K44P Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82 10 kV Relays K81A and K81B Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83 K81C Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84 K43A, K43B and K43C Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85 K43P and K43R Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86 12 kV Relays H-14 and H-16 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87 AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS KILOVAC High Voltage Relays and Contactors Table of Contents (Continued) 15 kV Relays H-8 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88 KC-14 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-89 KC-18 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-89 KC-2 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-90 KC-11 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-90 KC-12 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-90 KC-15 and KC-16 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-91 H-26 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-92 20/25 kV Relays H-19 and H-17 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-93 25 kV Relays K62A, K62B and K62C Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94 KC-20 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-95 KC-30 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-95 KC-22, KC-32 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-96 KC-28, KC-38 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-96 H-23 and H-24 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97 35 kV Relays KP61 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-98 K60C Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99 K61A and K61B Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100 K61C Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100 50 kV Relays K64C Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101 H-25 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101 70 kV Relays K70A and K70B Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-102 K70C Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-102 Mounting Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-103 Special Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-104, 7-104 Application Notes for EV/LEC Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-106, 7-107 Application Notes for MAP/CAP Contactors. . . . . . . . . . . . . . . . . . . . . . . . . 7-108 to 7-109 Application Notes on Coil Power Economizing using PWM Circuits. . . . . . 7-110, 7-111 7 KILOVAC High Voltage Relays and Contactors PAGE 3 KILOVAC High Voltage DC Contactors KILOVAC High Voltage DC Contactors Quick Reference Guide (MAP) Aerospace Military Product Series MAP101 MAP100 MAP200 MAP201 Main Contact Data Continuous Current A 100 100 500 350 Contact Voltage Range Vdc 12-900 12-900 12-900 12-900 Electrical Life at Rated Current, Cycles 25,000 15,000 1,000 5,000 270 Vdc, Resistive Load Overload (Make/Break) @ 350 Vdc A Rupture (Break only) @ 350 Vdc A Contact Arrangement 2,000/2,000 2,000 SPST 500/1,500 650/2,000 2,000/2,000 1,500 2,000 2,000 SPST SPST SPST X (NO) X (NO) X (NO) Contact Form Latch or Latch Contact Resistance @ Rated Current milliohms 0.75 0.5 0.2 0.3 Auxiliary Contact Data Contact Form/Quantity of Sets (Max.) Form A/1 Form A/1 Form A/1 Form A/1 Current Rating @ 30 Vdc (Ag/Au), Max. A 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 Ag 6V/15mA Ag 6V/15mA Ag 6V/15mA Ag 6V/15mA Minimum Signal Level Vdc/mAdc Au 5V/5mA Au 5V/5mA Au 5V/5mA Au 5V/5mA Dielectric Withstanding Voltage Contacts to Coil to All Other Points Vrms 1,500 1,500 2,200 2,200 Insulation Resistance Initially @ 500 Vdc megohms 100 100 100 100 At End of Life @ 500 Vdc megohms 50 50 50 50 Environmental Data Operating Temperature Range C -55 to +85 -55 to +85 -55 to +85 -55 to +85 Storage Temperature Range C -65 to +125 -65 to +125 -65 to +125 -65 to +125 Shock, 11ms, 1/2 Sine G's 20 20 20 20 Vibration, Sine (55-2,000 Hz) G's 20 20 20 20 Coil Transient Suppression No X, Yes/Latch, No Yes Yes Mechanical Data Operate Time @ 25C ms 40/20 40/20 40/20 40/20 (Including Bounce), Max./Typ. Release Time, Max. ms 15 15 15 15 Bounce Time, Max. ms 5 5 5 5 Mechanical Life, Min. Cycles 100,000 100,000 100,000 100,000 Weight (Nominal) lb. (kg) 0.79 (.35) 0.79 (.35) 0.95 (.43) 0.95 (.43) Coil Voltage (Nominal) Vdc 28 28 28 28 Note: Consult TE Connectivity for complete specifications, detailed performance characteristics and additional models. For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS KILOVAC High Voltage DC Contactors KILOVAC High Voltage DC Contactors Quick Reference Guide (Continued) (CAP) (EV) (LEV) Aerospace Commercial OEM/Commercial &Electric Vehicle Industrial Commercial CAP202 CAP200 CAP100 EV200A EV200B EV200P EV100 LEV100 LEV200 300 12-900 500100 12-900 12-900 500 12-900 500 12-900 500 12-900 100 12-900 100 900 500 12-900 10,000 1,0006,000 1,000 500 500 6,000 6,000 1,000 650/2,000 2,000 DPST 650/2,000 600/1000 2,000 1000 SPST SPST 650/2000 2000 SPST 650/1000 1000 SPST 650/1000 1000 SPST 600/1000 1000 SPST 600/1000 1000 SPST 650/2000 1000 SPST X(NO) Y(NC) X (LATCH) X(NO) X(NO) X(NO) 0.2 0.2 0.2 0.2 0.2 0.2 2X (NO) X (NO) X (NO) 0.2 0.2 0.2 Form C/4 2.0/0.1 Ag 6V/15mA Au 5V/5mA 2,200 100 50 -55 to +85 -65 to +125 Form A/2 2.0/0.1 Ag 6V/15mA Au 5V/5mA 2,200 Form C/1 2.0/0.1 Ag 6V/15mA Au 5V/5mA 2,200 100100 50 50 15 5 100,000 1.3 (.59) 28 -55 to +85 -65 to +125 2,200 2,200 2,200 2,200 100 50 100 50 100 50 100 50 -40 to +60 -40 to +85 -65 to +125 -65 to +125 30 (Closed)/ 30 30 20 20 20 10 (Open) 20 2020 20 10 20 Yes Yes Yes Yes Yes No 40/20 -55 to +85 -65 to +125 Form A/1 Form A/1 Form A/1 None Form X/1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 Ag 6V/15mA Ag 6V/15mA Ag 6V/15mA -- -- Au 5V/5mA Au 5V/5mA Au 5V/5mA 40/20 25/15 1510 5 5 100,000 100,000 0.95 (.43) 6.70 (190) 28 28 -40 to +85 -65 to +125 25/15 12 7 1,000,000 0.95 (.43) 9-36 25/15 25/15 2,000 Form X/1 2.0/0.1 Ag 6V/15mA Au 5V/5mA 2,200 100 100 50 50 -40 to +85 -65 to +125 20 -40 to +85 -65 to +125 -40 to +85 -65 to +125 20 20 20 Yes 20 No 20 No 25/15 25/15 25 10 5 1,000,000 0.42 (.19) 12/24/48 15 5 100,000 1.3 (.60) 12/24/48 15 15 15 5 5 5 100,000 100,000 1,000,000 0.95 (.43).99 (.53).28 (.130) 12/24 12/24 9-36 7 KILOVAC High Voltage DC Contactors For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. PAGE 5 KILOVAC High Voltage DC Contactors KILOVAC MAP101 Series Contactor with 1 Form A (SPST-NO) Contacts Rated up to 100 Amps, 12-900 Vdc Dual Contact Material (Cu/Mo) Product Facts n Dual contact material (copper/moly) designed for high current make and interrupt military aerospace, ground vehicle and naval applications n Hermetically sealed, intrinsically safe, operates in explosive/harsh environments with no oxidation or contamination of coils or contacts, during long periods of nonoperation n Comes standard with 1 SPST-NO Aux. contact n Not position sensitive, can be mounted in any orientation n RoHS versions available Coil Data Coil Voltage, Nominal/ Max -- 28/ 32 Vdc Coil Resistance @ 25C -- Contacts Close Coil -- 18 Contacts Open Coil -- 13 Pick Up/ Drop Out (Max) -- 16 Vdc (-55C to +25C) 18 Vdc (+25C to +85C) Coil Current (Max) @ 32Vdc/ -40C -- 4.0 A Coil Current On Time (Minimum Required to Latch) -- 40 ms Main Contacts -- Operate Time (Max) -- 40 ms Operate Bounce (Max) -- 5 ms Release Time -- 25 ms Auxiliary Contacts Operate/ Release -- Within 5 ms of main Physical Data Contact Arrangement -- Main Contacts -- SPST-Latching (form X) 1X Auxiliary Contact -- SPST-NO (form A) Dimensions -- See drawing Weight, Nominal -- 0.35 Kg (12.35 oz) Insulation Resistance -- Terminal to Terminal/ Terminals to Coil -- 100M min @ 500Vdc new 50M min @ 500Vdc end of life Note: 1 Continuous current rating is affected by conductors attached. Keep terminals below 150C max continuous. Environmental Data Shock, 11ms 1/2 Sine (Operating) -- 20 Gpeak Sine Vibration, 20 Gpeak -- 55-2000 Hz Random Vibration, 14.06 Grms -- 15 Hz (.002 G2/Hz), 100 Hz (.002 G2/Hz), 450 Hz (.12 G2/Hz), 900 Hz (.12 G2/Hz), 2000 Hz (.083 G2/Hz) Operating Temperature Range -- -55C to +85C Electrical Data Voltage Rating -- Main Contacts (max) -- 400 Vdc Auxiliary Contacts -- 30 Vdc Current Rating, Continuous -- Main Contacts 1 -- 100 A Auxiliary Contacts -- 3 A Contact Resistance -- Main Contacts -- 100 m max @ 1 amp 0.75 m max @ rated current Auxiliary Contacts -- 200 m max Electric Life at Rated Current 270 Vdc, Resistive Load -- 25,000 cycles Mechanical Life -- 1 million cycles Dielectric Withstand Voltage -- Terminal to Terminal/ Terminals to Coil -- 1mA max @ 1,300Vrms For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Ordering Information Typical Part Number MAP101 R B A F E Series: MAP101 = 100 Amp, 12-900VDC Contactor Dual Contact Material Contact Form: R - Latch with 1 SPST NO Aux. Coil Voltage: B = 28 Vdc Coil Lead Length: A = 15.3 in. (300 mm) Coil Terminal Connector: N = None F = Plug on Flying Lead, 9 Pin Micro-D Mounting & Power Terminals E = side mount with 2x#8 10-32 Female Power Terminals KILOVAC High Voltage DC Contactors KILOVAC MAP101 Series Contactor (Continued) Outline Dimensions Connector Pin-Out Not Connected Aux. NO Close Return Close Return +28Vdc Aux. Com. Open Return Open Return +28V 7 KILOVAC High Voltage DC Contactors 1 2 3 4 5 6 7 8 9 For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. PAGE 7 KILOVAC High Voltage DC Contactors KILOVAC MAP100 Series Contactor with 1 Form A (SPST-NO) Contacts Rated up to 100 Amps, 12-900 Vdc Product Facts n Solid copper contacts designed for high current carry military aerospace, ground vehicle and naval applications n Hermetically sealed, intrinsically safe, operates in explosive/ harsh environments with no contact oxidation or contamination of coil or contacts, during long periods of non- operation n Comes standard with 1 SPST-NO Aux. contact n Not position sensitive, can be mounted in any orientation n RoHS versions available Coil Data Coil Voltage, Nominal/ Max -- 28/ 32 Vdc Coil Resistance @ 25C -- Contacts Close Coil -- 18 Contacts Open Coil -- 13 Pick Up/ Drop Out (Max) -- 16 Vdc (-55C to +25C) 18 Vdc (+25C to +85C) Coil Current (Max) @ 32Vdc/ -40C -- 4.0 A Coil Current On Time (Minimum Required to Latch) -- 40 ms Main Contacts -- Operate Time (Max) -- 40 ms Operate Bounce (Max) -- 5 ms Release Time -- 25 ms Auxiliary Contacts Operate/ Release -- Within 5 ms of main Physical Data Contact Arrangement -- Main Contacts -- SPST-Latching (or NO Form X) 1X Auxiliary Contact -- SPST-NO (form A) Dimensions -- See drawing Weight, Nominal -- 0.35 Kg (12.35 oz) Insulation Resistance -- Terminal to Terminal/ Terminals to Coil -- 100M min @ 500Vdc new 50M min @ 500Vdc end of life Note: 1 Continuous current rating is affected by conductors attached. Keep terminals below 150C max continuous. Environmental Data Shock, 11ms 1/2 Sine (Operating) -- 20 Gpeak Sine Vibration, 20 Gpeak -- 55-2000 Hz Random Vibration, 14.06 Grms -- 15 Hz (.002 G2/Hz), 100 Hz (.002 G2/Hz), 450 Hz (.12 G2/Hz), 900 Hz (.12 G2/Hz), 2000 Hz (.083 G2/Hz) Operating Temperature Range -- -55C to +85C Electrical Data Voltage Rating -- Main Contacts (max) -- 400 Vdc Auxiliary Contacts -- 30 Vdc Current Rating, Continuous -- Main Contacts 1 -- 100 A Auxiliary Contacts -- 3 A Contact Resistance -- Main Contacts -- 100 m max @ 1 amp 0.75 m max @ rated current Auxiliary Contacts -- 200 m max Electrical Life at Rated Current, 270 Vdc, Resistive Load -- 15,000 cycles Mechanical Life -- 1 million cycles Dielectric Withstand Voltage -- Terminal to Terminal/ Terminals to Coil -- 1mA max @ 1,300Vrms For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Ordering Information Typical Part Number MAP100 R B A F E Series: MAP100 = 100 Amp, 12-900VDC Contactor Contact Form: H = NO with 1 SPST NO Aux. R - Latch with 1 SPST NO Aux. Coil Voltage: B = 28 Vdc Coil Lead Length: A = 15.3 in. (300 mm) Coil Terminal Connector: N = None F = Plug on Flying Lead, 9 Pin Micro-D Mounting & Power Terminals E = side mount with 2x#8 10-32 Female Power Terminals KILOVAC High Voltage DC Contactors KILOVAC MAP100 Series Contactor (Continued) Outline Dimensions Connector Pin-Out Not Connected Aux. NO Close Return Close Return +28Vdc Aux. Com. Open Return Open Return +28V 7 KILOVAC High Voltage DC Contactors 1 2 3 4 5 6 7 8 9 For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. PAGE 9 KILOVAC High Voltage DC Contactors KILOVAC MAP200 Series Contactor with 1 Form A (SPST-NO) Contacts Rated up to 500 Amps, 12-900 Vdc Product Facts n Designed to be the smallest, lightest weight, lowest cost sealed contactor in the industry with its current rating for military aerospace, ground vehicle and naval, high current applications n Built-in coil economizer (models requiring external economizer also available) n Optional auxiliary contact for easy monitoring of power contact position n Hermetically sealed -- intrinsically safe, operates in explosive/ harsh environments with no oxidation or contamination of coil or contacts, including long periods of non-operation n Versatile coil and power connections n RoHS versions available For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Performance Data Contact Arrangement, Power Contacts -- 1 Form A (SPST-NO) Rated Operating Voltage -- 12 - 900 VDC Continuous (Carry) Current, Typical -- 500 A @ 85C, 400 mcm conductors Consult Factory for required conductors for higher currents Make/Break Current at Various Voltages 1 -- See graph next page Break Current at 320VDC 1 -- 2,000 A, 1 cycle Contact Resistance, Typ. (@200A) -- 0.2 mohms Load Life -- See graph next page Mechanical Life -- 1 million cycles Contact Arrangement, Auxiliary Contacts -- 1 Form A (SPST-NO) Aux. Contact Current, Max. -- 2A @ 30VDC / 3A @ 125VAC Aux. Contact Current, Min. -- 100mA @ 8V Aux. Contact Resistance, Max. -- 0.417 ohms @ 30VDC / .150 ohms @ 125VAC Dielectric Withstanding Voltage -- 2,200 Vrms @ sea level Insulation Resistance @ 500VDC -- 100 megohms 2 Shock, 11ms 1/2 Sine, Peak, Operating -- 20 G Vibration, Sine, 50-2000Hz., Peak -- 20 G Operating Temperature -- -55C to +85C Weight, Nominal -- .95 lb. (.43 kg) Notes: 1 Main power contacts 2 50 at end of life AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Coil Operating Voltage (Valid Over Temperature Range) Voltage (Will Operate) 18-32VDC Voltage (Max.) 32VDC Pickup (Close) Voltage Max. 18VDC Hold Voltage (Min.) 10VDC Dropout (Open) Voltage (Min.) 2VDC Inrush Current (Max.) 4.5A Holding Current (Avg.) 0.5A Inrush Time (Max.) 100ms Ordering Information Typical Part Number MAP200 A R D E A Series: MAP200 = 500 Amp, 12-900VDC Contactor Contact Form: A = Normally Open H = Normally Open with Aux. Contacts Coil Voltage: R = 28 Vdc, Mechanical Economizer S = 28 Vdc, Electrical Cut-throat Economizer Coil Wire Length: A = 15.3 in (390 mm) D = Coil connector on relay (requires option "E" or "X" in next step). Coil Terminal Connector: N = No connector E = 9-pin subminiature "D" plug mounted on contactor housing X = Special configuration (consult factory) Mounting & Power Terminals: A = Bottom Mount & Male M8 x 1.25 Thread Terminals B = Bottom Mount & Female 1/4-20 Thread Terminals D = Bottom Mount & Female M6 x 1 Thread Terminals KILOVAC High Voltage DC Contactors KILOVAC MAP200 Series (Continued) Outline Dimensions 2.688 .01 (68.28 .26) 1.05 .01 (26.67 .26) LABEL 2 X M6 x 1 THREAD .45 (11.43) MIN DEPTH (11 THREADS) TORQUE VS THREAD ENGAGEMENT 8 TO 11 THREADS: 80 TO 100 IN-LB (9.1 TO 11.3 NM) 7 TO 8 THREADS: 70 TO 80 IN-LB (7.9 TO 9.1 NM) 5 TO 7 THREADS: 60 TO 70 IN-LB (6.8 TO 7.9) .800 .01 (20.3 .26) 3.289 .025 (83.54 .635) 2 X 10-32 THREAD THRU TORQUE: 15 TO 30 IN-LB (1.7 TO 3.3 NM) MAP200HR D-Sub Pin Out Coil+ = Pin 2 Coil - = Pin 6 Aux. COM = Pin 8 Aux. NO = Pin 4 MAP200AR Coil+ = Pin 2 Coil - = Pin 6 1.65 .01 (42.0 .26) WIRE VIEW REMOVED FOR CLARITY 2.245 .025 (57.02 .635) 2.523 .025 (64.08 .635) 1.431 .025 (36.35 .635) 2.20 .025 (55.81 .63) .546 .01 (13.87 .26) 3.17 .01 (80.48 .26) Estimated Make & Break Power Switching Ratings 650A Break Only Above 650A Make and Break Power Switching Region 100,000 10,000 900 120 VDC C VD VDC 100 400 Estimated Life (Cycles) 28 VDC C VD VDC 270 600 DC 0V 180 1,000 7 10 1 10 100 Load Current (A) 1,000 KILOVAC High Voltage DC Contactors 1 10,000 NOTES: 1) For resistive loads with 300H maximum inductance. Consult factory for inductive loads. 2) Estimates based on extrapolated data. User is encouraged to confirm performance in application. 3) End of life when dielectric strength between terminals falls below 50 megohms @ 500VDC. 4) The maximum make current is 650A to avoid contact welding. For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. PAGE 11 KILOVAC High Voltage DC Contactors KILOVAC MAP201 Series Contactor with 2 Form A (SPST-NO) Contacts Rated up to 350 Amps, 12-900 Vdc Dual Contact Material (Cu/Mo) Product Facts n Designed to be the smallest, lightest weight, lowest cost sealed contactor in the industry with its current rating for military aerospace n Built-in coil economizer (models requiring external economizer also available) n Optional auxiliary contact for easy monitoring of power contact position n Hermetically sealed -- intrinsically safe, operates in explosive/ harsh environments with no oxidation or contamination of coil or contacts, including long periods of non-operation n Versatile coil and power connections n RoHS versions available Coil Data Coil Voltage, Nominal/ Max -- 28/ 32 Vdc Pick Up (Max) -- 16 Vdc Inrush Current @ 28Vdc (Max) -- 3.5 A Inrush Time (Max) -- 100 ms Hold Current (Max) -- 0.32 A Drop Out -- 4 to 10 Vdc Main Contacts -- Operate Time (Max) -- 18 ms Operate Bounce (Max) -- 5 ms Release Time -- 18 ms Auxiliary Contacts Operate/ Release -- Within 5 ms of main Physical Data Contact Arrangement -- Power Contacts -- SPST-NO (form X) 2X Auxiliary Contacts 1 -- SPST-NO (form A) Dimensions -- See drawing Weight, Nominal -- 0.45 Kg (0.99 lb) Environmental Data Shock, 11ms 1/2 Sine (Operating) -- 20 Gpeak Sine Vibration, 20 Gpeak -- 55-2000 Hz Random Vibration, 14.06 Grms -- 15 Hz (.002 G2/Hz), 100 Hz (.002 G2/Hz), 450 Hz (.12 G2/Hz), 900 Hz (.12 G2/Hz), 2000 Hz (.083 G2/Hz) Operating Temperature Range -- -55C to +85C Electrical Data For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Voltage Rating -- Main Contacts (max) -- 400 Vdc Auxiliary Contacts -- 30 Vdc Current Rating, Continuous -- Main Contacts 2 -- 300 A Auxiliary Contacts -- 3 A Contact Resistance -- Main Contacts 3 -- 100 m max @ 1 amp 0.3 m max @ rated current Auxiliary Contacts -- 200 m max Hot Switching Performance (Polarity Sensitive) -- 600A make/ 265A break @ 270Vdc -- 11,000 cycles 550A make/ break @ 360Vdc -- 100 cycles 2000A capacitive make -- 100 cycles 2000A make/ break @ +360Vdc -- 5 cycles 1000A make/ break @ -360Vdc -- 2 cycles Mechanical Life -- 1 million cycles Dielectric Withstand Voltage -- Terminal to Terminal/ Terminals to Coil -- 1mA max @ 2,200Vrms AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Insulation Resistance -- Terminal to Terminal/ Terminals to Coil -- 100M min @ 500Vdc Notes: 1 Two form A available with electronic coil economizer, 1 form A available with mechanical coil economizer 2 Continuous current rating is affected by conductors attached. Keep terminals below 150C max continuous, 175C for 1 hour max, and 200C for 1 minute max. 3 Initial contact resistance may be higher than 0.3m, but will drop below within 30 minutes maximum Ordering Information Typical Part Number MAP201 A R D E A Series: MAP201 = 350 Amp, 12-900VDC Contactor Contact Form: A = Normally Open H = Normally Open with Aux. Contacts Coil Voltage: R = 28 Vdc, Mechanical Economizer S = 28 Vdc, Electrical Cut-throat Economizer Coil Wire Length: A = 15.3 in (390 mm) D = Coil connector on relay (requires option "E" or "X" in next step). Coil Terminal Connector: N = No connector E = 9-pin subminiature "D" plug mounted on contactor housing X = Special configuration (consult factory) Mounting & Power Terminals: A = Bottom Mount & Male M8 x 1.25 Thread Terminals B = Bottom Mount & Female 1/4-20 Thread Terminals D = Bottom Mount & Female M6 x 1 Thread Terminals KILOVAC High Voltage DC Contactors KILOVAC MAP201 Series Contactor (Continued) Outline Dimensions* Flying Lead "D" Connector Pin-Out 1 2 3 4 5 6 7 8 9 N/C AUX1 COM AUX2 COM RTN1 +28Vdc N/C AUX3 NO AUX2 NO RTN2 MAP200HR D-Sub Pin Out Coil+ = Pin 2 Coil - = Pin 6 Aux. COM = Pin 8 Aux. NO = Pin 4 7 MAP200AR Coil+ = Pin 2 Coil - = Pin 6 KILOVAC High Voltage DC Contactors *Alternate coil and main terminal connections available, consult factory. For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. PAGE 13 KILOVAC High Voltage DC Contactors KILOVAC CAP202 Series Aerospace Commercial Contactor with 2 Form X (DPST-NO), Contacts Rated up to 300 Amps, 12-600 Vdc Hot Switching Performance @ 400 Vdc (3) -- 100A make/break -- 10,000 cycles 250A make/break -- 2,500 cycles 700A break only -- 10 cycles Hot Switching Performance @ 270 Vdc (4) -- 100A make/break -- 40,000 cycles 250A make/break -- 7,500 cycles 2000A break only @ 370Vdc (5) -- 2 cycles Maximum Make Current -- 700A Dielectric Withstand Voltage over Life -- Terminal to Terminal/Terminals to Coil -- 1mA max @ 2,200Vrms Insulation Resistance over Life -- Terminal to Terminal/Terminals to Coil -- 50m min @ 500Vdc Mechanical Life -- 100,000 cycles Product Facts n Hermetically sealed n Up to 4X SPDT auxiliary switch outputs: 30 Vdc/2A max switching or 6V/5mA min. signal n Integrated coil economizer with coil suppression n EMC compliant - no radiated coil emission n Bidirectional switching main contacts not polarity sensitive n Mount in any orientation -not position sensitive Environmental Data Description Physical or Other Properties 2-pole single throw hermetically sealed DC contactor; 12-900 Vdc/350A per pole Weight: 0.79 Kg Not position sensitive Bi-directional switching High Voltage DC Converter Systems (ref schematic below) Test Equipment Power Distribution Physical Data DPST-NO CAP202 Contactor 270Vdc Components 540Vdc Components 270Vdc Return 270Vdc Supply + 270Vdc Components Electrical Compact epoxy-sealed resin enclosure occupies only about 4 in3 (65.5 cm3) Contact arrangement: DPST-No (2 form X) For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Number of SPDT Auxiliary Contacts per Contactor Type: CAP202AS -- None CAP202MS -- Two CAP202FS -- Four Performance Data Power Motion Control + Safe for harsh/corrosive environments No contacts oxidation over periods on non-use Applications 270Vdc Supply Hermetically sealed Voltage rating: 12-900 Vdc (main contacts); 30 Vdc (auxiliary) Mechanical life: 100,000 cycles AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Contact Arrangement -- Power Contacts -- DPST-NO (2 Form X) Auxiliary Switches -- SPDT (form C) Dimensions -- See drawings on next page Weight -- 0.79 Kg (1.74 lb.) Electrical Data Voltage Rating -- Main Contacts -- 12-900Vdc Auxiliary Catacts -- 30VdC Current Rating -- Main Contacts1 -- 350A/pole Auxiliary Catacts -- 3A Contact Resistance -- Main Contacts -- (2) 100 m max @ 1 amp 0.3 m max. @ 200A after 3 mins. Auxiliary Catacts -- 200 m max Shock, 11ms 1/2 sine (operating) -- 20G peak Sine Vibration, 10G peak -- 55-2,000 Hz. Random Vibration, 14 Grms -- 15 100 300 900 2000 Hz .01 .01 .2 .2 .01 G2/Hz Operating Temperature Range -- -55C to +85C Notes: 1 Using 4/0 conductor. Current rating is affected by attached conductor size and design. Keep terminals below 150C max. continuous, 175C for 2 hours max. and 200C for 1 minute max. For mounting large conductors, request terminal adapter PN 3-1618396-7. 2 Operational contact resistance is measured by millivolt drop across contacts a > 100A current. Initial contact resistance may be higher than 0.3m, but will drop below within 30 mins. max. 3 Voltage applied to each contact set separately. 4 Voltage applied across both contact sets in series. 5 May not pass 2,200 Vrms dielectric testing after second interrupt cycle. KILOVAC High Voltage DC Contactors KILOVAC CAP202 Series 12-900Vdc Contactors Outline Dimensions* Coil Data (-40 to +85C temp range unless otherwise noted) Voltage/Nominal Max. 28-32VDC Pickup Voltage Max. 16VDC Inrush Current @ 28 Vdc nominal/@32V maximum 3.4/6.0A Inrush Time (nominal/maximum) 75/150mS Hold Current @28V nominal / @32V maximum 0.27/0.48A Drop Out Voltage 3 to 8Vdc Internal Coil Suppression (max.) 60Vdc Main Contacts: Operate Time, nominal/maximum 13/20mS Main Contacts: Operate Bounce, nominal/maximum 3/10mS Main Contacts: Release Time, nominal/maximum 25mS Main Contacts: Release Time, maximum including Maximum arc time 7/12mS Ordering Information Typical Part Number CAP202 M S B F D Series: CAP202 = 2 form X, DPST-N0-DM Contactor Auxiliary Contact Outputs (SPDT form C): A = None M = Two F = Four 7 KILOVAC High Voltage DC Contactors Coil Voltage: S = 28V (with built-in electronically switched dual coil economizer) Coil and Aux. Wire Length: A = 15.3 inches B = 6 inches X = Customer Special Coil and Aux. Connector: N = None F = D Plug on flying leads (may affect wire length) Mounting & Power Terminals: D = 2X M5 Bottom Mount with 4X, M6 x 1 Female thread terminals Specifications are subject to change without notice. For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. PAGE 15 KILOVAC High Voltage DC Contactors KILOVAC CAP200 Series Contactor with 1 Form A (SPST-NO) Contacts Rated up to 500 Amps, 12-900 Vdc Product Facts n Designed to be the smallest, lightest weight, lowest cost sealed contactor in the industry with its current rating n Built-in coil economizer -- only 1.7W hold power @ 12VDC and it limits back EMF to 0V. (models requiring external economizer also available) n Optional auxiliary contact for easy monitoring of power contact position n Hermetically sealed -- intrinsically safe, operates in explosive/ harsh environments with no oxidation or contamination of coil or contacts, including long periods of non-operation n Versatile coil and power connections n RoHS versions available Performance Data Coil Operating Voltage (Valid Over Temperature Range) Voltage (Will Operate) 9-36VDC 32-95VDC 48-95VDC Voltage (Max.) 36VDC 95VDC 95VDC Pickup (Close) Voltage Max. 9VDC 32VDC 48VDC Hold Voltage (Min.) 7.5VDC 22VDC 34VDC Dropout (Open) Voltage (Min.) 6VDC 18VDC 27VDC Inrush Current (Max.) 3.8A 1.3A 0.7A 0.13A@12V, 0.03A@48V 0.02A@72V Holding Current (Avg.) 0.07A@24V Inrush Time (Max.) 130ms 130ms 130ms Ordering Information Typical Part Number CAP200 A A A N A Series: CAP200 = 500 Amp, 12-900VDC Contactor Contact Form: A = Normally Open H = Normally Open with Aux. Contacts Coil Voltage: A = 9-36VDC (1 = requires external coil economizer) D = 32-95VDC (2 = requires external coil economizer) J = 48-95VDC (3 = requires external coil economizer) R = 28 Vdc with mechanical economizer Coil Wire Length: A = 15.3 in (390 mm) D = Coil connector on relay (requires option "E" or "X" in next step) Coil Terminal Connector: N = None E = 9-pin subminiature "D" plug mounted on contactor housing F = 9-pin subminiature "D" plug mounted on 15.3 in (390 mm) flying leads. X = Special configuration (consult factory) For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Mounting & Power Terminals: A = Bottom Mount & Male 10mm x 8 Terminals AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Contact Arrangement, Power Contacts -- 1 Form A (SPST-NO) Rated Operating Voltage -- 12 - 900 VDC Continuous (Carry) Current, Typical -- 500 A @ 85C, 400 mcm conductors Consult Factory for required conductors for higher currents Make/Break Current at Various Voltages 1 -- See graph next page Break Current at 320VDC 1 -- 2,000 A, 1 cycle 3 Contact Resistance, Typ. (@200A) -- 0.2 mohms Load Life -- See graph next page Mechanical Life -- 1 million cycles Contact Arrangement, Auxiliary Contacts -- 1 Form A (SPST-NO) Aux. Contact Current, Max. -- 2A @ 30VDC / 3A @ 125VAC Aux. Contact Current, Min. -- 100mA @ 8V Aux. Contact Resistance, Max. -- 0.417 ohms @ 30VDC / .150 ohms @ 125VAC Dielectric Withstanding Voltage -- 2,200 Vrms @ sea level Insulation Resistance @ 500VDC -- 100 megohms 2 Shock, 11ms 1/2 Sine, Peak, Operating -- 20 G Vibration, Sine, 80-2000Hz., Peak -- 20 G Operating Temperature -- -40C to +85C Weight, Nominal -- .95 lb. (.43 kg) Notes: 1 Main power contacts 2 50 at end of life 3 Does not meet dielectric & IR after test, 1700 amp for unit with Aux. Contacts KILOVAC High Voltage DC Contactors KILOVAC CAP200 Series (Continued) Outline Dimensions M8 x 1.25 POWER TERMINALS (HARDWARE SUPPLIED): 2 X M8 WASHER, STAINLESS 2 X M8 LOCKWASHER - SPLIT RING, STAINLESS 2 X M8 x 1.25 NUT, STAINLESS TORQUE 80 TO 100 IN-LB (8.8 TO 11 NM) 1.05 .01 (26.67 .26) 2.29 .02 DIA (58.19 .51) A1 "+" POSITIVE TERMINAL A2 "-" NEGATIVE TERMINAL .225 .01DIA (5.72 .26) MOUNTING HARDWARE (NOT SUPPLIED): 2 X M5 BOLT 2 X M5 LOCKWASHER 2 X M5 NARROW WASHER TORQUE 15 TO 30 IN-LB (1.7 TO 3.3 NM) 1.65 .01 (42.0 .26) 2.688 .01 (68.28 .26) AUXILIARY CONTACT LEADS WHITE = AUXILIARY CONTACT (WHEN ORDERED) BLACK = - COIL RED = + COIL COIL LEADS SEE COIL WIRE LENGTH IN P/N 2.20 .025 (55.81 .63) 2.85 .025 (72.3 .63) STAINLESS 2.04 .02 DIA (51.94 .51) .55 .025 (14.04 .63) 2.05 .02 (52 .51) 2.58 .02 (65.6 .51) 3.17 .01 (80.48 .26) .5 .01 (12.6 .26) Estimated Make & Break Power Switching Ratings 650A Break Only Above 650A Make and Break Power Switching Region 100,000 10,000 900 120 VDC C VD VDC 100 400 Estimated Life (Cycles) 28 VDC C VD VDC 270 600 DC 0V 180 1,000 7 10 1 10 100 Load Current (A) 1,000 KILOVAC High Voltage DC Contactors 1 10,000 NOTES: 1) For resistive loads with 300H maximum inductance. Consult factory for inductive loads. 2) Estimates based on extrapolated data. User is encouraged to confirm performance in application. 3) End of life when dielectric strength between terminals falls below 50 megohms @ 500VDC. 4) The maximum make current is 650A to avoid contact welding. For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. PAGE 17 KILOVAC High Voltage DC Contactors KILOVAC CAP120 Series 900 Vdc Contactor Product Facts n Suitable for application in harsh and explosive environments n No contact oxidation over periods of non-use n Size reduced version of MAP/CAP 100 Series contactors n Bidirectional switching n Main contacts not polarity sensitive n Panel mount n Not position sensitive: mounts in any orientation n Integrated dual-coil electronic "cut-throat" economizer with suppression Applications n Energy storage systems n Power distribution n High-current battery systems n Lithium ion battery systems n Solar power Schematic A1 A2 RED + BLK _ Coil Wire: 22 AWG M22759/11 Coil + Integrated Economizer with Suppression Description Performance Data Mechanical Data Designed for harsh environments and loads, the new KILOVAC CAP120 contactor from TE Connectivity (TE) offers exceptional performance for a device this small and light. A reducedsize version of our popular MAP and CAP series contactors, the CAP120 contactor's small size and light weight opens up new application possibilities for a 150 A/600 Vdc device. Electrical Data Shock -- 11ms 1/2 sine (operating): 20 g peak Sine Vibration -- 25 g peak: 55 to 2000 Hz Random Vibration -- 13.3 grms: Operating Temperature Range -- 40C to +85C Weight -- 0.14 kg Sealing -- Hermetic High break levels--1000 A at 400 Vdc and 600 A at 600 Vdc--help increase system flexibility and reliability. CAP120 contactors provide reliable and long-lasting performance in military ground, military and commercial aerospace, and marine applications. For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Contact Arrangement -- SPST-NO (form X) Voltage Rating -- 600 Vdc Current Rating -- 150 A continuous Contact Resistance -- 0.6 m Contact Voltage Drop @ 150 A -- 80 mV max. Hot-Switching Performance, Resistive Load @ 600 Vdc -- 100 A Make/Break -- 1000 cycles 600 A Break -- 5 cycles 600 A Make -- 25 cycles Hot-Switching Performance, Resistive Load @ 400 Vdc -- 150 A Make/Break -- 3250 cycles 1000 A Break Only -- 5 cycles Maximum Pulse Through Closed Contacts -- 1250 A Dielectric Withstanding Voltage over Life -- Terminal to Terminal -- 1 mA max. @2800 Vrms Terminals to Coil -- 1 mA max. @1500 Vrms Insulation Resistance over Life -- Terminal to Terminal -- 100 M @ 500 Vdc new Terminals to Coil -- 50 M min. @ 500 Vdc end of life Mechanical Life -- 100,000 cycles min. KILOVAC High Voltage DC Contactors KILOVAC CAP120 Series (Continued) Coil Operating Voltage (Valid Over Temperature Range) 28 Vdc 28 Vdc 16 Vdc 12 Vdc 6 Vdc min. 6.5 200 4.5 A 0.15 A 100 ms 8 ms 3 ms 5 ms 42 V Coil Voltage, nom.: Pick Up Voltage, max. over temperature range: Hold Voltage, min: Dropout Voltage: Pickup Coil Resistance: Hold Coil Resistance: Coil Inrush Current @ 28 Vdc nom.: Hold Current @28 Vdc Coil Inrush Time, max.: Operate Time: Operate Bounce: Release Time: Coil Suppression (max.) 12 Vdc 12 Vdc 8.5 Vdc 7 Vdc 7 Vdc max. 2.5 51 4.5 A 0.25 A 100 ms 15 ms 5 ms 5 ms 42 V 1.82 0.70 MOUNTING HARWARE (NOT SUPPLIED) M4 BOLT, LOCKWASHER, AND NUT A2 A1 LOAD TERMINALS (NOT SUPPLIED) M5 BOLT, LOCKWASHER, AND NUT COIL WIRES 22 AWG (M22759/11) 15 INCH LENGTH 1.78 1.50 7 0.32 KILOVAC High Voltage DC Contactors 2.12 Coil Voltage Description Part No. 28 Vdc CAP120ASANG 2-1618403-6 12 Vdc CAP120AVANG 2-1618411-9 For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. PAGE 19 KILOVAC High Voltage DC Contactors KILOVAC KHR500 High-Voltage 600 Amp Contactors Product Facts n 600 A carry n 3300 A break at 400 Vdc n 4000 A make current n Bidirectional load switching n Safe for application in harsh and explosive environments n Not position sensitive n Rugged, robust design n Smaller and up to 64% lighter than our popular EV500 BUBBA contactors n Integrated dual-coil electronic "cut throat" economizer n Switches voltages from 28 to 1000 Vdc Applications n Aerospace Description n Ground vehicles n Marine n Solar n Automotive n Energy storage systems n UL 508 recognized for US and Canada TE Connectivity's (TE) KILOVAC KHR500 "BUBBA II" feature smaller size and lighter weight than our popular EV500 "BUBBA" high-voltage contactors. Capable of handling inrush currents as high 4000 A, the contactors are hermetically sealed for use in hazardous or explosive environments. Configured as a single-pole, single-throw device, the contactors can handle voltages from 28 to 1000 Vdc and continuous 600 A currents. Because it is not polarity sensitive, the contactor allows bidirectional load switching. An integrated coil economizer reduces the power required to hold the contacts closed to 320 mA at 24 Vdc. A single-pole, double-throw auxiliary switch supports 3 A @ 125 Vrms or 1 A @ 30 Vdc, and low-level signals down to 5 V/10 mA. Electrical Data Main Contact Arrangement -- SPST (1 Form X) Auxiliary Contact Arrangement -- SPDT (1 For C) Voltage Rating: Main Contact -- 28 to 1000 Vdc Auxiliary Contacts -- (3 A @ 125 Vrms or 1 A @ 30 Vdc) Current Rating: Main Contacts, Continuous -- 600 A Contact Resistance: Main Contacts -- 0.3 m max @ 600 A Auxiliary Contacts -- 150 m @ 1 A Hot Switching Performance @ 400 Vdc: 200 A Make/Break -- 4000 cycles 600 A Make/Break -- 10 cycles 3000 A Make/Break -- 3 cycles 4000 A Make or Pulse through Closed Contacts (1 ms risetime, 10 ms pulse duration) -- 10 cycles Dielectric Withstand Voltage -- 1 mA max @ 2800 Vrms Insulation Resistance @ 500 Vdc -- 100 M initial, 50 M end of life Mechanical/Environmental Contact Arrangement -- Power Contacts: SPST (1 Form X) Auxiliary Switches -- SPDT (1 Form C) Shock -- (11 ms 1/2 sine, (operat- ing): 25 g (Z axis)/35 g (X, Y axes) peak Sine Vibration -- 55 to 2000 Hz: 25 g (Z axis), 35 g (X, Y axes) AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Random Vibration (13.3 Grms): @ 15 Hz: .002 g2/Hz @ 100 Hz: .002 g2/Hz @ 450 Hz: .12 g2/Hz @ 900 Hz: .12 g2/Hz @ 2000 Hz: .083 g2/Hz Operating Temperature Range -- -55 to +125C Weight -- 0.56 kg (1.2 lb.) Mechanical Life -- 100,000 cycles, min. Hermetically Sealed for Operation in Harsh/Explosive Environments Coil Data 24/28 Vdc models at 20C Consult TE for 12 Vdc model or other voltages Coil Voltage -- 24 Vdc nom./32 Vdc max. Pick Up -- 13 Vdc Dropout Voltage (max.) -- 8 Vdc Coil Resistance -- 3.2 /85 Pickup/Hold Inrush Current (max @ 24 Vdc) -- 4.5 A Inrush Time (max.) -- 100 ms Timing -- Operate Time -- 25 ms typ. Operate Bounce -- 5 ms max. Release Time -- 15 ms max. Simultaneity (Aux/Main) -- 5 ms max. KILOVAC High Voltage DC Contactors KILOVAC KHR500 High-Voltage 600 Amp Contactors (Continued) KHR500 Part Numbering System K S A N L Series: Contact Form: A = Form X, SPST-NO, Double Make K = Form X, SPST-NO, Double Make with 1 SPDT Auxiliary Contact Coil Voltage: S = 24/28 Vdc, Electric Cut-Throat Economizer V = 12 Vdc, Electric Cut-Throat Economizer Coil Leads: A = 15 Coil/Auxiliary Leads (No Connector) Coil/Auxiliary Connector: N = None Mounting: L = Bottom Mount, No. 10 Hole, 5/16-24 Female Terminal Main Power Connection Product Dimensions 5/16-24 UNF (2X) 7 THREADS DEPTH HARDWARE SUPPLIED: FLAT WASHER LOCK WASHER 5/16-24 X 3/8 BHCS MAX TORQUE 100 IN-LBS AUX NC (WHT) AUX NO (BRN) COIL RTN (BLK) AUX COM (GRN) COIL +VDC (RED) O 2.29 [58.17] COIL WIRES AND AUX WIRES 22 AWG 6" LENGTH (FROM TOP CAP) 2.73 [69.34] 2.23 [56.64] 2.13 [54.10] LABEL O .23 [5.84] 2X 1.05 [26.67] 2.29 [68.33] .53 [13.46] #10 MOUNTING HARDWARE (NOT SUPPLIED) TORQUE 30 IN-LBS MAX 3.17 [80.52] Continuous Current vs. Ambient Temperature Part Numbers Part 800 Part No. Carry Current (A) 700 24/28 VDC 600 12 VDC 500 No Aux Contact KHR500ASANL KHR500AVANL 400 Aux Contact KHR500KSANL KHR500KVANL 300 200 100 0 0 25 50 7 KILOVAC High Voltage DC Contactors 2 x 3/0 AWG or 350 kcmil Conductor Max Terminal Temp <170C Contacts Closing into >10 A dc Schematic Schematic 75 100 125 A2 A1 Ambient Temperature (C) + (Red) _ (Black) Coil + Integrated Electronic Cut-Throat Economizer NO (Brown) COM (Green) NC (White) PAGE 21 KILOVAC High Voltage DC Contactors KILOVAC K1K High-Voltage Contactor Product Facts n Handles up to 1000 A/1000 V n Suitable for application in harsh and explosive environments n No contact oxidation over periods of non-use n Bidirectional switching n Main contacts not polarity sensitive n Bottom or buss bar mount n Integrated dual-coil electronic "cut-throat" economizer with internal suppression n One of the smallest 1000 A/1000 V hermetically-sealed contactors in the industry Applications n Energy Storage/Battery Storage n Power Distribution * Alternative Energy n Electric Vehicles (Military and Commercial) n Test Equipment Description Electrical Data Environmental/Mechanical As one of the smallest, lowest cost, hermetically sealed 1000 A/1000 V switching devices in the Industry, the KILOVAC K1K contactor from TE Connectivity (TE) operates reliably in harsh and explosive environments without oxidation or contamination of contacts, even after long periods of non-operation. The K1K is well suited for power switching at voltages as low as 5 VDC and as high as 1000 VDC. Typical applications include main disconnect contactor for large battery bank applications, for carry and interrupt battery fault currents and other high current applications, power/motor control circuit isolation, and circuit protection and safety. Main Contacts Shock -- 11 ms, 1/2 sine (operating), 20 g peak Sine Vibration -- 20 gpeak (operating) 55 to 2000 Hz Operating Temperature Range -- -40C to +105C Weight, Nominal -- 1.02 kg Sealing -- Hermetic AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Contact Arrangement -- SPST-NO (Form X) Voltage Rating (Max.) -- 1000 VDC Current Rating, Continuous -- 1000 A (At 25C ambient with four 4/0 conductors or equivalent) Current Rating, Short Term -- 1200 A/180 sec Contact Resistance -- 0.2 m max. at rated current Hot-Switching Performance, Resistive Load -- 50 A/1000 VDC -- 25,000 cycles 130 A/1000 VDC -- 10,000 cycles 200 A/1000 VDC -- 3500 cycles 100 A/600 VDC -- 10,000 cycles 240 A/600 VDC -- 2000 cycles 1000 VDC/1200 A -- 4 cycles (Break Only) Maximum Pulse Through Closed Contacts -- 6000 A (half cycle, 60 Hz) Dielectric Withstanding Voltage over Life: Between Open Contacts -- 2800 Vrms Contacts to Coil -- 2800 Vrms/4000 VDC End of Life Between Open Contacts -- 2200 Vrms Insulation Resistance over Life, Terminal to Terminal; Terminals to Coil -- Beginning of Life -- 100 M min. @ 500 VDC End of Life -- 50 M min. @ 500 VDC Mechanical Life -- 100,000 cycles minimum Coil Data Coil Data @ 20C (Internal Two-Coil Economizer) Coil Voltage Range -- 24 VDC nom./32 VDC max. Maximum Pickup Current -- 5.5 A Nominal Holding Current -- 0.33 A Pickup Voltage -- 18 VDC Dropout Voltage -- 10 VDC Pickup Pulse (Max) -- 75 ms Coil Resistance 5% -- 4.7 Pickup/72 Hold Coil Holding Power -- 8 W Main Contacts -- Operate Time (Max) -- 50 ms Operate Bounce (Typ.)-- 5 ms Release (Typ.) -- 8 ms KILOVAC High Voltage DC Contactors KILOVAC K1K High-Voltage Contactor (Continued) K Part Numbering System 1K 06 X 024E A F A Brand: K = KILOVAC Basic Rating: 1K = 1000 V/1000 A Size: 06 = Size 06 (EV202 Package) Configuration: X = Form X, Normally Open Coil Voltage: 012E = 12 V Coil Economized 024E = 24 V Coil Economized Coil lead length: A = 15 inches Contact Termination: F = Finned Heat Sink Bus Bar (Nickel-Plated Aluminum) G = Flat Bus Bar (Nickel-Plated Copper) H = Four 1/4-20 UNC Female Threads, .187" Deep* Mounting: A = Bottom Mount *User furnished bus bar must be equivalent to four 4/0 conductors. Torque to 45-55 in-lbs. per connection (5.1 - 6.2 Nm) 4.52 [114.8] O0.23 [5.8] 0.68 [17.3] 3.79 [96.3] 3.31 [84.1] 1.36 [34.5] O0.38 [9.65] 7 3.92 [99.6] 0.50 [12.7] KILOVAC High Voltage DC Contactors LEAD LENGTH 15 0.5 [381 12.7] (2 LEADS, RED/BLACK) A PAGE 23 KILOVAC High Voltage DC Contactors KILOVAC KCS01 Current-Sensing High-Voltage Contactor Product Facts n Saves space by eliminating the need for external sensor n Simplifies design nFlexible configuration for application needs n Suitable for many applications in harsh, explosive, and corrosive environments nNo oxidation or contamination of contacts, including long periods of non-operation n Extremely small size n Lightweight contactor: 145 grams n Bidirectional switching n Main contacts not polarity sensitive n Not position sensitive: mounts in any orientation nIntegrated dual-coil electronic economizer with coil suppression nEMC compliant: no radiated coil emissions Applications n Energy Storage/Battery Storage n Power Distribution n Power Motion Control n High-Voltage DC Converter Systems n Alternative Energy nMilitary and Commercial Electric Vehicles n Test Equipment Description Performance Data Mechanical/Environmental The new KILOVAC Current Sensing contactors from TE Connectivity (TE) eliminate the need for a discrete current sensor, saving the customer money, weight and space. The sensor function also has a programmable trip feature, allowing for immediate, delayed or disabled trip. Main Contacts Mechanical Life -- 1,000,000 cycles Shock -- 11 ms 1/2 sine (operating), 20 g peak Sine Vibration -- 20 g peak (operating), 55-2000 Hz Operating Temperature Range -- -40 to +105 C RoHS Compliant Weight, Nominal -- 145 grams Hermetically Sealed -- Safe for many harsh/corrosive environments Nonoxidizing -- No contact oxidation over periods of nonuse Mounting -- Not position-sensitive Noise Emission (at 100 mm distance) -- 70 dBa In addition to the integrated current sensing feature, KCS01 contactors are rugged and hermetically sealed, making them suitable for a variety of applications in harsh, corrosive and explosive environments. Even after long periods of non-operation, the contacts are impervious to oxidation and contamination. The KCS01 contactor is extremely small and lightweight. It features bidirectional switching and an integrated dual-coil electronic economizer with internal coil suppression, and can be mounted in any orientation. Main contacts are not polarity sensitive, and the KCS01 is EMC compliant with no radiated coil emissions. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Contact Arrangement -- SPST-NO (Form X) Voltage Rating, Switching -- 600 VDC max. Current Rating, Continuous -- 100 A Current Rating, Short Term -- 200 A / 3 minutes Contact Resistance, Main Contacts -- 0.75 m max. at rated current Hot-Switching Performance, Resistive Load 1 A / 600 VDC -- 1,000,000 cycles 100 A / 28 VDC -- 100,000 cycles 100 A / 400 VDC -- 25,000 cycles 100 A / 600 VDC -- 20,000 cycles 1000 A / 28 VDC -- 100 cycles 1000 A / 400 VDC -- 10 cycles 1000 A / 600 VDC -- 5 cycles Maximum Pulse Through Closed Contacts -- 1250 A (half cycle, 60 Hz) Dielectric Withstanding Voltage -- Between Open Contacts -- 2200 Vrms Contacts to Coil -- 2200 Vrms / 1500 VDC Insulation Resistance (Terminal to Terminal; Terminals to Coil) -- Beginning of Life -- 100 M min. @ 500 VDC End of Life -- 50 M min. @ 500 VDC KILOVAC High Voltage DC Contactors KILOVAC KCS01 Current-Sensing High-Voltage Contactor (Continued) Coil Data At 20C (Internal Two-Coil Economizer) Coil Voltage Range 12 V Coil 24 V Coil 9-14 VDC 18-28 VDC Nominal Pickup Current 4.5 A 4.0 A Nominal Holding Current 0.25 A 0.125 A Pickup Voltage 9 VDC 18 VDC Dropout Voltage 6 VDC 12 VDC Pickup Pulse (max) 40 ms 40 ms Coil Resistance 5% Coil Holding Power 2.5 Pickup/54 Hold 2.7 W 7.5 Pickup/210 Hold 2.7 W Operate Time (max) 20 ms 20 ms Operate Bounce (max) 3 ms 3 ms Release Time 5 ms 5 ms Main Contacts: Current Sensing Sensing Range (8% accurate -40C to +105C) 10 - 150 A 10 - 150 A Null Output @ I = 0 2.5 (0.04) VDC 2.5 (0.04) VDC Output Voltage vs. Current (VDC) V(I) = I (.013) + 2.50 Current Trip Point vs. Setpoint Resistance See Pages 5 and 6 Hysteresis (-40C to + 105C) 8% of Full Scale Output 0.70 [17.8] LEADS ARE 26 AWG. LENGTH = 15" +/- 0.5" FROM TOP OF TERMINAL SEAT MOUNTING - 2 PLCS (HARDWARE NOT SUPPLIED) 2 X M4 BOLT, LOCKWASHER AND WASHER TORQUE: 20 IN-LBS (2.3 NM) MAX O1.56 [39.5] RED = +Vcoil BLACK = RETURN PURPLE = TRIP DELAY/DISABLE ORANGE = CURRENT SENSE POWER WHITE = CURRENT SENSE OUTPUT BLUE = Rx CONNECTION YELLOW = Rx CONNECTION LOAD TERMINALS-2 PLCS (HARDWARE NOT SUPPLIED) 2 X M5 BOLT, LOCKWASHER AND WASHER TORQUE: 30-40 IN-LBS (3.4 TO 4.5 NM) DEPTH: 7 THREADS MAX O0.18 [4.6] OBSERVE PROPER POLARITIES FOR CONTROL LINES UNTERMINATED WIRES - USE ESD HANDLING PROCEDURES 1.82 [46.2] 2.12 [53.8] CURRENT FLOW INTO THIS TERMINAL FOR INCREASING SENSOR OUTPUT >2.5 VDC 1.79 [45.5] 1.72 [43.7] 1.50 [38.1] 0.30 [7.6] Part Numbering System KCS 01 X 024E A C 7 A KILOVAC High Voltage DC Contactors Series: KCS = KILOVAC Current Sensing Size: 01 = Size 01 (EV100 Package) Configuration: X = Form X, Normally Open Coil Voltage: 012E 12 V Coil Economized 024E 24 V Coil Economized Coil Lead Length: A = 15 Inch Coil Leads Mounting Hardware: C = M5 Female Terminals Mounting style: A = Bottom Mount PAGE 25 KILOVAC High Voltage DC Contactors KILOVAC KCS01 Current-Sensing High-Voltage Contactor (Continued) Load Life: Resistive Load Switching Current Carry vs. Time ( #4 AWG conductor) 10,000 100,000 1000 10,000 1000 100 400 V 600 V 28 V 10 1 100 Time (s) Cycles 1,000,000 10 1 1 10 100 0.1 1000 Current (A) 0.01 Break only above 600 A 0 200 400 600 800 1000 1200 Current (A) Trip Function/Trip Delay (10-150A) 200 Trip Current |A| 180 160 140 120 Trip Setpoint Resistor (10 A to 150 A) 100 Connect Rx across Blue and Yellow for Trip Setpoint 80 Connect Purple to RTN to Disable Trip Function or Connect Purple to External Capacitor Tied to RTN to Delay Trip, 7 ms/F 60 40 20 0 Connect Orange to V+ To Enable Trip and Current Sensing 100 1000 10,000 100,000 External Resistor Value (Ohms) Reset Tripped Contacts by Cycling V+ Off to On Intrinsic Trip Delay (Blue/Yellow Not Connected to Rx) = 14 ms Input RTN (Black) Main Contact Current (A) Output Trip Disable/ Time Delay (Purple) Trip Set Rx (Blue) Trip Set Ax (Yellow) Hall Output (V) (White) Control (Orange) V+ (Red) 0 Vnom 0 0 NON-ACTIVE NON-ACTIVE 0 ON (NO TD) 0 0 0 0 NON-ACTIVE NON-ACTIVE 0 OFF (NO TD) 1 0 0 0 OPEN OPEN 2.5 OFF RELAY TRIP OPEN AFTER 14 ms Main Contacts Top Post 1 Vnom 0 180 A 7% OPEN 30K 4.84 (2.5 when relay trip) 1 0 then 1 remove and re-apply power 0 167 A OPEN 30K 2.5 ON (NO TD) 1 Vnom 0 0 X 2.5 ON (NO TD) 1 Vnom 0 180 A 7% X 4.84 ON (NO TD) 1 0 0 0 X 2.5 OFF (NO TD) 1 Vnom 0 0 1 F is added between Purple and RTN 30K 2.5 ON (NO TD) 1 Vnom 0 180 A 7% 10 F is added between Purple and RTN 30K 4.84 (2.5 when relay trip) RELAY TRIP OPEN AFTER 82 ms 1 Vnom 0 180 A 7% 10 F is added between Purple and RTN 30K 4.84 (2.5 when relay trip) RELAY TRIP OPEN AFTER 720 ms 1 0 then Vnom remove and re-apply power 0 167 A 10 F is added between Purple and RTN 30K 2.5 ON (NO TD) GND (TRIP DISABLE) GND (TRIP DISABLE) GND (TRIP DISABLE) AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS KILOVAC High Voltage DC Contactors KILOVAC KCS01 Current-Sensing High-Voltage Contactor (Continued) Timing Diagram Vcontrol (0range) 0V V+in (Red) 0V I trip I (Contacts) 0A Closed Contacts Open >14 ms 14 ms Connection Diagram GND ENERGIZE/CLOSE CONTACTS USING SWITCH OR SOLID STATE DEVICE-LOW SIDE DRIVE SHOWN KCS01X012/KCS01X024 RTN BLACK SENSOR_OUT WHITE V(I) V(I) = I (.013) + 2.50 +24/12 VDC RED V+ (12 OR 24 VSX NOM) SENSOR/TRIP EN ORANGE CONNECT ORANGE TO V+ FOR SENSINGSENSING ACTIVE ONLY WITH LOW SIDE DRIVE ENABLED AS SHOWN SENSOR INPUT SINK 15 mA MAX BLUE Rx Rx DISABLE/DELAY PURPLE YELLOW Rx CONNECT Rxx VALUE PER TRIP FUNCTION/TRIP DELAY GRAPH TO SET TRIP LEVEL N/C Cx 7 ms/F GND GND LEAVE PURPLE NC FOR TRIP ENABLE GROUND FOR TRIP DISABLE CONNECT Cx FOR TRIP DELAY, 7 ms/F GND 7 KCS01X012/KCS01X024 ENERGIZE/CLOSE CONTACTS USING SWITCH OR SOLID STATE DEVICE-HIGH SIDE DRIVE SHOWN RTN BLACK SENSOR_OUT WHITE KILOVAC High Voltage DC Contactors V+ (12 OR 24 VDC NOM) V(I) V(I) = I (.013) + 2.50 +24/12 VDC RED SENSOR/TRIP EN ORANGE CONNECT ORANGE TO V+ FOR SENSINGSENSING ACTIVE WITH/WITHOUT HIGH SIDE DRIVE ENABLED AS SHOWN SENSOR INPT SINK 15 mA MAX BLUE Rx DISABLE/DELAY PURPLE N/C Cxx Rxx YELLOW Rx CONNECT Rxx VALUE PER TRIP FUNCTION/TRIP DELAY GRAPH TO SET TRIP LEVEL GND 7ms/F GND LEAVE PURPLE NC FOR TRIP ENABLE GROUND FOR TRIP DISABLE CONNECT Cxx FOR TRIP DELAY, 7 ms/F PAGE 27 KILOVAC High Voltage DC Contactors KILOVAC KCS03 Current-Sensing High-Voltage Contactor Product Facts nSaves space by eliminating the need for external sensor n Simplifies design n Flexible configuration for application needs n Suitable for application in many harsh, explosive, and corrosive environments n No oxidation or contamination of contacts, including long periods of non-operation n Extremely small size n Lightweight contactor: 500 grams n Bidirectional switching n Main contacts not polarity sensitive n Not position sensitive: mounts in any orientation nIntegrated dual-coil electronic economizer with coil suppression nEMC compliant: no radiated coil emissions Applications n Energy Storage/Battery Storage n Power Distribution n Power Motion Control n High-Voltage DC Converter Systems n Alternative Energy n Military and Commercial Description Performance Data General Characteristics The new KILOVAC Current Sensing contactors from TE Connectivity (TE) eliminate the need for a discrete current sensor, saving the customer money, weight and space. The sensor function also has a programmable trip feature, allowing for immediate, delayed or disabled trip. Physical Data Mechanical/Environmental Contact Arrangement -- SPST-NO (Form X) Voltage Rating, Switching -- 600 VDC max. Current Rating, Continuous -- 600 A Current Rating, Short Term -- 1200 A / 30 sec Contact Resistance, Main Contacts -- 0.2 m max. at rated current Hot-Switching Performance, Resistive Load 1 A / 600 VDC: 1,000,000 cycles 100 A / 28 VDC: 100,000 cycles 100 A / 400 VDC: 25,000 cycles 100 A / 600 VDC: 20,000 cycles 1000 A / 28 VDC: 100 cycles 1000 A / 400 VDC: 10 cycles 1000 A / 600 VDC: 5 cycles Maximum Pulse Through Closed Contacts -- 3000 A (half cycle, 60 Hz) Dielectric Withstanding Voltage -- Between Open Contacts: 2800 Vrms Contacts to Coil: 2800 Vrms / 4000 VDC Insulation Resistance (Terminal to Terminal; Terminals to Coil) -- Beginning of Life -- 100 M min. @ 500 VDC End of Life -- 50 M min. @ 500 VDC Mechanical Life-- 1,000,000 cycles Shock-- 11 ms 1/2 sine (operating), 20 g peak Sine Vibration-- 20 g peak (operating), 55-2000 Hz Operating Temperature Range-- -40 to +105 C RoHS Compliant Weight, Nominal-- 500 grams Hermetically Sealed-- Safe for many harsh/corrosive environments Nonoxidizing-- No contact oxidation over periods of nonuse Mounting-- Not position-sensitive Noise Emission (at 100 mm distance)-- 70 dBa In addition to the integrated current sensing feature, KCS03 contactors are rugged and hermetically sealed, making them suitable for a variety of applications in harsh, corrosive and explosive environments. Even after long periods of non-operation, the contacts are impervious to oxidation and contamination. The KCS03 contactor is extremely small and lightweight. It features bidirectional switching and an integrated dual-coil electronic economizer with internal coil suppression, and can be mounted in any orientation. Main contacts are not polarity sensitive, and the KCS03 is EMC compliant with no radiated coil emissions. For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS KILOVAC High Voltage DC Contactors KILOVAC KCS03 Current-Sensing High-Voltage Contactor (Continued) O2.29 [58.17] HARNESS: WIRE LENGTHS 15" NOMINAL ALL CONDUCTORS M22759/11, 22 AWG RED = V+ BLACK = RTN WHITE (2 EA) AUX COM-NO PURPLE = TRIP DISABLE/PROGRAM TIME DELAY ORANGE = CONNECT TO V+ FOR TRIP SENSING AND CURRENT SENSING BROWN = CURRRENT SENSE OUTPUT BLUE = Rx YELLOW = Rx O0.23 [5.84] 1.05 [26.67] 2.69 [68.33] OBSERVE PROPER POLARITIES FOR CONTROL LINES UNTERMINATED WIRES - USE ESD HANDLING PROCEDURES 3.17 [80.52] M5 x 1.25 NUT HARDWARE INCLUDES FLAT WASHER AND LOCKWASHER MAX. TORQUE: 90 IN-LBS. [10 N-m] CURRENT FLOW INTO THIS TERMINAL FOR INCREASING SENSOR OUTPUT >2.5 VDC 0.50 [12.7] Part Numbering System 2.87 [72.9] KCS 03 X 024E A A A Series: KCS = KILOVAC Current Sensing Size: 03 = Size 03 (EV200 Package) Configuration: X = Form X, Normally Open 7 Coil Voltage : 012E 12 V Coil Economized 024E 24 V Coil Economized KILOVAC High Voltage DC Contactors Coil Lead Length: A = 15 Inch Coil Leads Mounting Hardware: A = M8 Male Terminals Mounting Style: A = Bottom Mount Part Numbers Coil Voltage Part No. 12 VDC KCS03X012EAAA 24 VDC KCS03X024EAAA PAGE 29 KILOVAC High Voltage DC Contactors KILOVAC KCS03 Current-Sensing High-Voltage Contactor (Continued) Load Life: Resistive Load Switching 1,000,000 Cycles 100,000 10,000 1000 100 400 V 600 V 28 V 10 1 1 10 100 1000 Current (A) Break only above 650 A Current Carry vs. Time (350 KCMIL Conductor) Time (s) 1000 Time Rate 100 10 10 1 1 0.1 0.01 0 500 1000 1500 2000 2500 3000 3500 Current (A) Trip Function/Trip Delay (50 A to 630 A) 650 600 550 500 Trip Current |A| 450 400 350 300 250 200 150 100 50 0 0 1000 AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS 2000 3000 4000 External Resistor Value (Ohms) 5000 6000 Temperature Rise (C/s) 100 10,000 KILOVAC High Voltage DC Contactors KILOVAC KCS03 Current-Sensing High-Voltage Contactor (Continued) Trip Setpoint Resistor (10 A to 150 A) Connect Rx across Blue and Yellow for Trip Setpoint Connect Purple to RTN to Disable Trip Function or Connect Purple to External Capacitor Tied to RTN to Delay Trip, 7 ms/F Connect Orange to V+ To Enable Trip and Current Sensing Reset Tripped Contacts by Cycling V+ Off to On Intrinsic Trip Delay (Blue/Yellow Not Connected to Rx) = 14 ms Input Output Sensing Control (Orange) V+ (Red) RTN (Black) Main Contacts (Current +/ADC) Trip Disable/ Time Delay (Purple) Trip Set Rx (Blue) Trip Set Ax (Yellow) 0 9-14 or 18-28 0 0 NON-ACTIVE NON-ACTIVE 0 0 0 0 NON-ACTIVE NON-ACTIVE 0 OFF (NO TD) OFF (NO TD) V+ 0 0 0 OPEN OPEN 2.5 OFF OFF RELAY TRIP OPEN AFTER 14 ms RELAY TRIP OPEN AFTER 14 ms Hall Output (VDC) (Brown) Main Contacts Aux. Contact (N.O.) White/White 0 ON (NO TD) ON (NO TD) 4.145 (2.5 V when tripped) V+ 9-14 or 18-28 0 500 A 7% OPEN 4.2 K V+ 0, then 9-14 or 18-28 remove and re-apply power 0 464 OPEN 4.2 K 2.5 ON (NO TD) ON (NO TD) 0 0 X 2.5 ON (NO TD) ON (NO TD) 0 500 A 7% X 4.145 ON (NO TD) ON (NO TD) X 2.5 OFF (NO TD) OFF (NO TD) 4.2 K 2.5 ON (NO TD) ON (NO TD) RELAY TRIP OPEN AFTER 82 ms RELAY TRIP OPEN AFTER 82 ms RELAY TRIP OPEN AFTER 720 ms RELAY TRIP OPEN AFTER 720 ms ON (NO TD) ON (NO TD) V+ V+ 9-14 or 18-28 9-14 or 18-28 0 0 0 V+ 9-14 or 18-28 0 0 V+ 9-14 or 18-28 0 500 A 7% V+ 9-14 or 18-28 0 500 A 7% V+ 0, then 9-14 or 18-28 remove and re-apply power 0 464 1 F is added between these two wires 10 F is added between these two wires 100 F is added between these two wires 100 F is added between these two wires 4.2 K 4.2 K 4.2 K 4.145 (2.5 V when tripped) 4.145 (2.5 V when tripped) 2.5 7 KILOVAC High Voltage DC Contactors V+ GND (TRIP DISABLE) GND (TRIP DISABLE) GND (TRIP DISABLE) PAGE 31 KILOVAC High Voltage DC Contactors KILOVAC KCS03 Current-Sensing High-Voltage Contactor (Continued) Timing Diagram Vcontrol (0range) 0V V+in (Red) 0V I trip I (Contacts) 0A Closed Contacts Open >14 ms 14 ms Connection Diagram GND ENERGIZE/CLOSE CONTACTS USING SWITCH OR SOLID STATE DEVICE-LOW SIDE DRIVE SHOWN KCS03X012/KCS03X024 RTN BLACK AUX_COM WHITE +24/12 VDC RED V+ (12 OR 24 VDC NOM) SENSOR/TRIP EN ORANGE AUX_NO WHITE SENSOR_OUT BROWN BLUE Rx Rx DISABLE/DELAY PURPLE YELLOW Rx CONNECT Rxx VALUE PER TRIP FUNCTION/TRIP DELAY GRAPH TO SET TRIP LEVEL N/C Cx 7 ms/F GND V(I) V(I) = I (.0034) + 2.50 CONNECT ORANGE TO V+ FOR SENSINGSENSING ACTIVE ONLY WITH LOW SIDE DRIVE ENABLED AS SHOWN SENSOR INPUT SINK 15 mA MAX GND LEAVE PURPLE NC FOR TRIP ENABLE GROUND FOR TRIP DISABLE CONNECT Cx FOR TRIP DELAY, 7 ms/F GND KCS03X012/KCS03X024 ENERGIZE/CLOSE CONTACTS USING SWITCH OR SOLID STATE DEVICE-HIGH SIDE DRIVE SHOWN RTN BLACK +24/12 VDC RED V+ (12 OR 24 VDC NOM) SENSOR/TRIP EN ORANGE V(I) BLUE Rx DISABLE/DELAY PURPLE N/C GND 7 ms/F GND AUX_NO WHITE SENSOR_OUT BROWN V(I) = I (.0034) + 2.50 CONNECT ORANGE TO V+ FOR SENSINGSENSING ACTIVE WITH/WITHOUT HIGH SIDE DRIVE ENABLED AS SHOWN SENSOR INPT SINK 15 mA MAX Cxx AUX_COM WHITE LEAVE PURPLE NC FOR TRIP ENABLE GROUND FOR TRIP DISABLE CONNECT Cxx FOR TRIP DELAY, 7 ms/F AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Rxx YELLOW Rx CONNECT Rxx VALUE PER TRIP FUNCTION/TRIP DELAY GRAPH TO SET TRIP LEVEL KILOVAC High Voltage DC Contactors KILOVAC EV202 High-Voltage Contactors Product Facts n Suitable for application in harsh, explosive, and corrosive environments n EMC compliant: no radiated coil emissions n Extremely small size n Lightweight contactor: 0.77 kg n Bidirectional switching n Main contacts not polarity sensitive n Not position sensitive: mounts in any orientation n Integrated dual-coil electronic economizer with coil suppression Applications n Energy Storage/Battery Storage n Power Distribution n Power Motion Control n High-Voltage DC Converter Systems n Alternative Energy n Military and Commercial Electric Vehicles n Test Equipment Description Electrical Data Hermetically sealed and designed for harsh environments and loads, KILOVAC EV202 high-voltage contactors from TE Connectivity (TE) offers exceptional performance in an extremely small and lightweight device. Configuration: Double pole, single throw, normally open Voltage Rating, Main Contacts: 600 VDC, max. Make Current: 700 A, max. DWV and Insulation Resistance over Life, Terminal to Terminal/ Terminals to Coil Dielectric Withstand Voltage: 1 mA max @ 2200 Vrms Insulation Resistance: 50 m min. @ 500 VDC Hot Switch Life: Available with 12 or 24-V coils, the contactors are suited to 270 and 400-VDC power systems. They are available with two optional auxiliary contacts. High break levels--2000 A at 270 VDC and 700 A at 400 VDC--help increase system flexibility and reliability. 250 A 700 A Break Only 2000 A Break Only @ Voltage 270 VDC 400 VDC 270 VDC 400 VDC 400 VDC 270 VDC Hot Switch Life 40,000 10,000 7500 2500 10 2 Coil Data (over -40C to +85C unless noted) Coil Voltage, nom./max. Pick up voltage, max. (applied as step voltage only) 12/16 VDC 8 VDC 24/32 VDC 16 VDC Dropout Voltage Coil Inrush Current @ V-nom., max. Coil Inrush Time, nom./max. Hold Current @ V-nom., max. Coil Suppression, max. Operate Times Operate Time, nom./max. Operate Bounce, nom./max. Release Time, nom./max. 2.5-4 VDC 5A 75/150 ms 0.6 A 40 VDC 3-8 VDC 4.5 A 75/150 ms 0.2 A 60 VDC 13/20 ms 3/10 ms 5 ms 25 ms 13/20 ms 3/10 ms 5 ms 25 ms Release Time, max. (including max. arc time) PAGE 33 7 KILOVAC High Voltage DC Contactors EV202 contactors provide reliable and long-lasting performance in military and commercial electric ground vehicles, energy storage systems, and power distribution and motion control applications. Make/Break Current 100 A KILOVAC High Voltage DC Contactors KILOVAC EV202 High-Voltage Contactors (Continued) Optional Auxiliary Contacts Series: EV202 = Two Form X, DPST-NO-DM Contactor Environmental Operating Temperature Range -- -55C to + 85C Hermetically Sealed -- Safe for harsh/corrosive environments Nonoxidizing -- No contact oxidation over periods of nonuse Auxiliary Contact Outputs (SPDT form C): A = None M = Two Coil Voltage: S = 24 V V = 12 V (With Built-In Dual Coil Economizer) RoHS Compliant Economizer -- Integrated electronically switched coil economizer with coil suppression EMC Compliant -- No radiated coil emissions Coil and Aux Wire Length (inches): A = 15.3 B=6 X = Customer-Specified Configuration Mechanical Shock -- 11 ms 1/2 sine (operating): 20 g peak Sine Vibration -- 10 g peak: 10 to 2000 Hz Random Vibration -- 14 grms: Hz g2/Hz 15 0.01 100 0.01 300 0.2 900 0.2 Coil and Aux Connector: N = None F = D-Subminiature Plug on Flying Leads (May Affect Wire Length) 2000 0.01 Mounting and Power Terminals: D = Two M5 Bottom Mount with Four M6 X 1 Female thread terminals Bidirectional Switching -- Main contacts not polarity sensitive Mounting -- Mounts in any orientation; not position sensitive Mechanical Life -- 100,000 cycles Weight -- 0.77 kg Product Dimensions (Inches) Typical Schematic (Shown with Auxiliary Contacts) 1.00 [25.40] M6 x 1.0-8H Female Thread B1 B2 A1 A2 B1 AUX: COM 1 O0.228 [5.79] 1.00 [25.40] EV202 M S B F D Typical Part Number Configuration -- Two SPDT switch outputs Ratings -- 30 VDC/2A switching or 5 V/5 mA signal NO 2 NC 3 3.312 [84.12] COIL RTN 4 9-Pin Sealed D-Subminiature Plug 5.0 [127] (Not to Scale) COIL POS 5 BLANK 6 Economizer Circuit B1 AUX: COM 7 NO 8 NC 9 DB9 Plug Connector 0.50 [12.70] 2.32 [58.93] 2.72 [69.09] 2.420 [61.47] 3.79 [96.27] AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS 2.790 [70.87] HOLD COIL PICK-UP COIL KILOVAC High Voltage DC Contactors KILOVAC EV200 Series Contactor With 1 Form X (SPST-NO) Contacts Rated 500+ Amps, 12-900 Vdc Product Facts n Designed to be the smallest, lightest weight, lowest cost sealed contactor in the industry with its current rating (500+A carry, 2000A interrupt at 320VDC) n Built-in coil economizer -- only 1.7W hold power @ 12VDC and it limits back EMF to 0V. Models requiring external economizer also available n Optional auxiliary contact for easy monitoring of power contact position n Hermetically sealed -- intrinsically safe, operates in explosive/ harsh environments with no oxidation or contamination of coil or contacts, during long periods of non-operation n Versatile coil/power connections n UL Recognized for the U.S. and Canada (File E208033) All contact ratings & coil versions may not be UL Recognized n CE marked for EC applications n AIAG QS9000 designed, built and approved n RoHS versions available Performance Data EV200 Series Contactor (CZONKA Relay, Type Coil Operating Voltage (Valid Over Temperature Range) Voltage (Will Operate) 9-36VDC 32-95VDC 48-95VDC Voltage (Max.) 36VDC 95VDC 95VDC Pickup (Close) Voltage Max. 9VDC 32VDC 48VDC Hold Voltage (Min.) 7.5VDC 22VDC 34VDC Dropout (Open) Voltage (Min.) 6VDC 18VDC 27VDC Inrush Current (Max.) 3.8A 1.3A 0.7A 0.13A@12V, 0.03A@48V 0.02A@72V Holding Current (Avg.) 0.07A@24V Inrush Time (Max.) 130ms 130ms 130ms Ordering Information Typical Part Number EV200 A A A N A Series: EV200 = 500+ Amp, 12-900VDC Contactor Contact Form: A = Normally Open H = Normally Open with NO Aux. Contacts G = Normally Open with NC Aux. Contacts Coil Wire Length: A = 15.3 in (390 mm) Notes: 1 Main power contacts 2 50 at end of life 3 Does not meet dielectric & IR after test, 1700 amp for unit with Aux. Contacts Coil Terminal Connector: N = None C=M olex Mini-fit Jr, 2 Skt, Female 18-24, P/N 39-01-2020 & 39-00-0060 +red is pin 1 (A length only) For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Mounting & Power Terminals: A = Bottom Mount & Male 10mm x M8 Terminals PAGE 35 7 KILOVAC High Voltage DC Contactors Coil Voltage: A = 9-36VDC (1 = requires external coil economizer) D = 32-95VDC (2 = requires external coil economizer) J = 48-95VDC (3 = requires external coil economizer) R = 28VDC with Mechanical Economizer Contact Arrangement, Power Contacts -- 1 Form A (SPST-NO) Rated Operating Voltage -- 12 - 900 VDC Continuous (Carry) Current, Typical -- 500 A @ 85C, 400 mcm conductors Consult Factory for required conductors for higher (500+ A) currents Make/Break Current at Various Voltages 1 -- See graph next page Break Current at 320VDC 1 -- 2,000 A, 1 cycle 3 Contact Resistance, Typ. (@200A) -- 0.2 mohms Load Life -- See graph next page Mechanical Life -- 1 million cycles Contact Arrangement, Auxiliary Contacts -- 1 Form A (SPST-NO) Aux. Contact Current, Max. -- 2A @ 30VDC / 3A @ 125VAC Aux. Contact Current, Min. -- 100mA @ 8V Aux. Contact Resistance, Max. -- 0.417 ohms @ 30VDC / .150 ohms @ 125VAC Operate Time @ 25C -- Close (includes bounce), Typ. -- 15 ms Bounce (after close only), Max. -- 7 ms Release (includes arcing), Max @ 2000A -- 12 ms Dielectric Withstanding Voltage -- 2,200 Vrms @ sea level (leakage <1mA) Insulation Resistance @ 500VDC -- 100 megohms 2 Shock, 11ms 1/2 Sine, Peak, Operating -- 20 G Vibration, Sine, 80-2000Hz., Peak -- 20 G Operating Ambient Temperature -- -40C to +85C Weight, Nominal -- .95 lb. (.43 kg) KILOVAC High Voltage DC Contactors KILOVAC EV200 Series (CZONKA Relay, Type III) (Continued) Outline Dimensions M8 x 1.25 POWER TERMINALS (HARDWARE SUPPLIED): 2 X M8 WASHER, STAINLESS 2 X M8 LOCKWASHER - SPLIT RING, STAINLESS 2 X M8 x 1.25 NUT, STAINLESS TORQUE 80 TO 100 IN-LB (8.8 TO 11 NM) 1.05 .01 (26.67 .26) 2.29 .02 DIA (58.19 .51) A1 "+" POSITIVE TERMINAL A2 "-" NEGATIVE TERMINAL .225 .01DIA (5.72 .26) MOUNTING HARDWARE (NOT SUPPLIED): 2 X M5 BOLT 2 X M5 LOCKWASHER 2 X M5 NARROW WASHER TORQUE 15 TO 30 IN-LB (1.7 TO 3.3 NM) 1.65 .01 (42.0 .26) 2.688 .01 (68.28 .26) AUXILIARY CONTACT LEADS WHITE = AUXILIARY CONTACT (WHEN ORDERED) BLACK = - COIL RED = + COIL COIL LEADS SEE COIL WIRE LENGTH IN P/N 2.20 .025 (55.81 .63) 2.85 .025 (72.3 .63) STAINLESS 2.04 .02 DIA (51.94 .51) .55 .025 (14.04 .63) 2.05 .02 (52 .51) 2.45 .02 (62.23 .51) 3.17 .01 (80.48 .26) .5 .01 (12.6 .26) Estimated Make & Break Power Switching Ratings 650A Break Only Above 650A Make and Break Power Switching Region 100,000 10,000 900 VDC 100 120 C VD VDC 400 Estimated Life (Cycles) 28 VDC C VD VDC 270 600 DC 0V 180 1,000 EV200 Capacitive Make Test Curves for Pre-Charged Motor Controller 700 10 650 600 80% Minimum Pre Charge 550 1 10 100 Load Current (A) 1,000 500 10,000 NOTES: 1) For resistive loads with 300H maximum inductance. Consult factory for inductive loads. 2) Estimates based on extrapolated data. User is encouraged to confirm performance in application. 3) End of life when dielectric strength between terminals falls below 50 megohms @ 500VDC. 4) The maximum make current is 650A to avoid contact welding. 450 Current (A) 1 90% Nominal Pre Charge 400 350 300 250 200 150 100 50 For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS 0 0.0 0.5 1.0 Time (ms) 1.5 2.0 KILOVAC High Voltage DC Contactors KILOVAC EV200B Series Contactor With 1 Form Y (SPST-NC) Contacts Rated 500+ Amps, 12-900 Vdc Product Facts n Normally closed version of popular EV200 series contactors n Designed to be the smallest, lowest cost, lightest weight sealed contactor in the industry at its current rating n Optional auxiliary contacts for monitoring position of power contacts n Hermetically sealed -- operates in explosive/ harsh environments with no oxidation or contamination of coil or contacts during long periods of non-operation n Not position sensitive, can be mounted in any orientation n RoHS versions available Hold (Min) -- 6/12 Vdc Dropout (Min) -- 4/9 Vdc Pickup Current, Peak 6 @ 25C --6A Operate Specs @ 25C -- Operate Time (Typ) -- 15 ms Operate Bounce (Max) -- 5 ms Release Time (Typ) -- 15 ms Economizer Operating Frequency -- 18 kHz Hold Current -- 0.9A/12 Vdc 0.3A/24 Vdc Physical Data Contact Arrangements -- Main Contacts -- SPST, Normally Closed Dimensions -- See drawing Weight, Nominal -- .95 lb. (.43 kg) Environmental Data Shock, 11ms 1/2 Sine (Operating) -- 30 Gpeak (Closed) 10 Gpeak (Open) Sine Vibration, 10 Gpeak -- 55-2000 Hz Random Vibration, 7.1 Grms -- 15 Hz (.001 G2/Hz), 100 Hz (.04 G2/Hz), 1000 Hz (.04 G2/Hz), 1500 Hz (.02 G2/Hz) Operating Temperature Range -- -40C to +85C Coil Data 4 Nominal Coil Voltage 5 -- Low range -- 9.6-14 Vdc High range -- 19-28 Vdc Pick Up (Max) @ 25C -- 9.6/18.5 Vdc Pick Up @ Max Coil Temperature -- 10.5/22 Vdc Ordering Information EV200 B A A N A Electrical Data Typical Part Number Voltage Rating -- Main Contacts (Max) -- 750 Vdc Current Rating, Continuous -- Main Contacts 1 -- 500A Contact Resistance -- Main Contacts 2 -- 0.2 m max above 300A 0.3 m max between 50 and 300A Hot Switching Performance (Positive Polarity) 3 -- 200A make/ break @ 270Vdc -- 10,000 cycles 600A make/ break @ 360Vdc -- 100 cycles 800A break only @ 360Vdc -- 15 cycles 1500A break only @ 360Vdc -- 1 cycle Mechanical Life (Min) -- 1 million cycles Dielectric Withstand Voltage -- Terminal to Terminal/ Terminals to Coil -- 1mA max @ 2,200 Vrms Series: EV200 = 500+ Amp, 12-900VDC Contactor Contact Form: B = Normally Closed 7 D = Normally Closed, 1 SPDT Aux. Coil Voltage (with Economizer): A = 12/24 Vdc KILOVAC High Voltage DC Contactors For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Insulation Resistance -- Terminal to Terminal/ Terminals to Coil -- 100M min @ 500Vdc new 50M min @ 500Vdc end of life Notes: 1 Ambient conditions and conductor design affect rating. Terminal temperature rise should be 75C max above ambient. Keep relay terminals below 150C max continuous, 175C max for two hours, and 200C for 1 minute. 2 Stabilized reading. Contact resistance may exceed spec in the first 10 minutes of current carry. 3 Units are polarity sensitive. Approximately 50% de-rating for reverse polarity switching. Consult factory for review of specific requirements. 4 Over temperature range unless noted. 5 Voltage ranged sensed by contactor 10 ms after application of source voltage. 6 Pickup duration 100 ms. Coil Terminals: A = 15.3 in. (300 mm) Coil Terminal Connector: N = None Mounting & Power Terminations: A = Bottom Mount & Male 10 Max. M8 Threaded Terminals PAGE 37 KILOVAC High Voltage DC Contactors KILOVAC EV200B Series Contactor (Continued) Outline Dimensions 2.29 .02 DIA (58.19 .51) 1.05 .01 (26.67 .26) A1 "+" POSITIVE TERMINAL M8 x 1.25 POWER TERMINALS (HARDWARE SUPPLIED): 2 X M8 WASHER, STAINLESS 2 X M8 LOCKWASHER - SPLIT RING, STAINLESS 2 X M8 x 1.25 NUT, STAINLESS TORQUE 80 TO 100 IN-LB (8.8 TO 11 NM) A2 "-" NEGATIVE TERMINAL .225 .01DIA (5.72 .26) MOUNTING HARDWARE (NOT SUPPLIED): 2 X M5 BOLT 2 X M5 LOCKWASHER 2 X M5 NARROW WASHER TORQUE 15 TO 30 IN-LB (1.7 TO 3.3 NM) 1.65 .01 (42.0 .26) 2.688 .01 (68.28 .26) AUXILIARY CONTACT LEADS WHITE = AUXILIARY CONTACT (WHEN ORDERED) BLACK = - COIL RED = + COIL COIL LEADS 2.20 .025 (55.81 .63) SEE COIL WIRE LENGTH IN P/N 2.85 .025 (72.3 .63) STAINLESS 2.04 .02 DIA (51.94 .51) .55 .025 (14.04 .63) 3.17 .01 (80.48 .26) For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS 2.05 .02 (52 .51) 2.45 .02 (62.23 .51) .5 .01 (12.6 .26) KILOVAC High Voltage DC Contactors KILOVAC EV200P Series Latching Contactor With 1 Form X (SPST Latch) Contacts Rated 500+ Amps, 12-900 Vdc Product Facts n Latching version of popular EV200 Series n Designed to be the smallest, lowest cost, lightest weight sealed contactor in the industry at its current rating n Optional auxiliary contacts for monitoring position of power contacts n Hermetically sealed -- operates in explosive/ harsh environments with no oxidation or contamination of coil or contacts during long periods of non-operation n Not position sensitive, can be mounted in any orientation n RoHS versions available Pick Up/Latch (Max) @ 25C -- 9 Vdc Hold (Min) -- N/A Reset (Max)/Dropout (Min) -- 9 Vdc Duty Cycle, Max 7 -- 20% Coil Resistance @ 25C -- 2.5 Operate Specs @ 25C -- Operate Time (Typ) -- 15 ms Operate Bounce (Max) -- 7 ms Release Time (Max) -- 15 ms Physical Data Contact Arrangements -- Main Contacts -- SPST, Latching Auxiliary Contacts 1 -- Up to 2 Form A Dimensions -- See drawing Weight, Nominal -- .95 lb. (.43 kg) Environmental Data Shock, 11ms 1/2 Sine (Operating) -- 30 Gpeak Sine Vibration, 20 Gpeak -- 55-2000 Hz Random Vibration, 14.06 Grms -- 15 Hz (.002 G2/Hz), 100 Hz (.002 G2/Hz), 450 Hz (.12 G2/Hz), 900 Hz (.12 G2/Hz), 2000 Hz (.083 G2/Hz) Operating Temperature Range -- -40C to +85C Electrical Data Coil Data 5 Nominal Coil Voltage 6 -- 12 Vdc Ordering Information Typical Part Number EV200 P 4 A N A Series: EV200 = 500+ Amp, 12-900VDC Contactor 7 Contact Form: P = Latching F = Latching with 1 SPDT Aux. Coil Voltage: 4 = 12 Vdc 5 = 24 Vdc 6 = 48 Vdc KILOVAC High Voltage DC Contactors For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Voltage Rating -- Main Contacts (Max) -- 750 Vdc Current Rating, Continuous -- Main Contacts 2 -- 500A Contact Resistance -- Main Contacts 3 -- 0.2 m max above 300A 0.3 m max between 50 and 300A Hot Switching Performance (Positive Polarity) 4 -- 200A make/ break @ 270Vdc -- 10,000 cycles 600A make/ break @ 360Vdc -- 100 cycles 800A break only @ 360Vdc -- 15 cycles 2000A break only @ 360Vdc -- 1 cycle Mechanical Life (Min) -- 1 million cycles Dielectric Withstand Voltage -- Terminal to Terminal/ Terminals to Coil -- 1mA max @ 2,200 Vrms Insulation Resistance -- Terminal to Terminal/ Terminals to Coil -- 100M min @ 500Vdc new 50M min @ 500Vdc end of life Notes: 1 Product can be configured alternately with form B or C auxiliary switches if required. This changes the product part number, depending on specific auxiliary configuration. Consult TE for availability and part number 2 Ambient conditions and conductor design affect rating. Terminal temperature rise should be 75C max above ambient. Keep relay terminals below 150C max continuous, 175C max for two hours, and 200C for 1 minute. 3 Stabilized reading. Contact resistance may exceed spec in the first 10 minutes of current carry. 4 Units are polarity sensitive. Approximately 50% de-rating for reverse polarity switching. Consult factory for review of specific requirements. 5 Over temperature range unless noted. Suggested coil pulse = 50-100 ms. 6 24V and 48V coils available on request -- consult factory. 7 Intermittent Duty Coil. Coil overheating can occur if duty cycle Coil Terminations: A = 15.3 in. (300 mm) Coil Termination Connector: N = None Mounting & Power Terminals: A = Bottom Mount & Male 10mm x M8 Threaded Terminals PAGE 39 KILOVAC High Voltage DC Contactors KILOVAC EV200P Series Latching Contactor (Continued) Outline Dimensions For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS KILOVAC High Voltage DC Contactors KILOVAC EV100 Series Contactor With 1 Form X Contacts Rated 100 Amps Continuous, 600 Vdc Product Facts n Hermetically sealed n Operates in explosive/ harsh environments without oxidation or contamination of contacts, during long periods of non-operation n 8kV isolation between open contacts permits use for high voltage isolation and carry n Coil economizer allows for operation between 9-36 VDC n Designed and built in accordance with AS 9100 Description Operate time: 30 ms max. Low cost, 600 Vdc, 100 amp, hermetically sealed DC contactor Physical or Other Properties Economized coil for low power consumption between 9-36 VDC Bottom mount, not position sensitive Safe for harsh/corrosive environments No contact oxidation over periods of non-use Mechanical One million cycle mechanical life Small size: 1.5" x 1.5" approximately Applications Weight: 130 grams Power/motor control circuit isolation, circuit protection and safety in industrial machinery Physical Data Automotive battery switching and backup Solar inverter switching Automotive pre-charge Test Equipment Electrical Contact arrangement: SPST-NO (Form X., Double Make) Voltage rating: 5-600 Vdc at 100 Amps 50K cycles Make/Break: 50 Amps at 400 Vdc 25K cycles Make/Break: 50 Amps at 600 Vdc Performance Data Contact Arrangement, Main Contacts -- SPST-NO (Form X) Dimensions -- See drawings on next page Weight -- 4.58 oz (130g) Electrical Data Voltage Rating, Main Contacts Switching (Max) -- 750VDC Current Rating, Main Contacts Switching -- Continuous 1 -- 100A Short Term, 3 Minutes 2 -- 200A Contact Voltage Drop, Main Contacts -- 0.05 max @ rated current Operate & Release Time Operate Time Max. -- 30ms Operate Bounce Max. -- 5ms Release Time -- 10ms Environmental Data Shock, 11ms 1/2 sine (operating) -- 20G peak Sine Vibration, 20G peak -- 55-2,000 Hz. Operating Temperature Range -- -40C to +85C Noise Emission (at 100 mm distance) -- 70dB(a) Notes 1 8.4mm2 conductor. Current rating is affected by conductor size. Keep terminals below 150C max. continuous. 2 3 minutes at +40C ambient, 1 minute at -80C ambient with 8.4mm2 (#8 AWG) conductor. Holding current: 0.15 Amps at 24 Vdc PAGE 41 7 KILOVAC High Voltage DC Contactors Power distribution For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Hermetically sealed Resistive Load Performance (polarity sensitive) -- 50A make/break @ +400Vdc -- 50,000 cycles 50A make/break @ +600Vdc -- 25,000 cycles 100A make/break @ +400Vdc -- 6,000 cycles 100A make/break @ +600Vdc -- 5,000 cycles 100A make/break @ -400Vdc -- 1,000 cycles 100A make/break @ -600Vdc -- 25 cycles 200A make/break @ +400Vdc -- 500 cycles 200A make/break @ +600Vdc -- 200 cycles 1,000A break only @ +400Vdc -- 5 cycles 600A break only @ +600Vdc -- 5 cycles 600A make only -- 10 cycles Maximum Short Circuit Current (1/2 cycle, 60 Hz) -- 1,250A (through closed contacts) Dielectric Withstand Voltage -- Between Open Contacts -- 2,2000Vrms Contacts to Coil -- 1,500Vrms/4,000Vdc Insulation Resistance, Terminal to Terminal / Terminals to Coil -- When New -- 100 megohms, min. @ 500Vdc At End of Life -- 50 megohms, min. @ 500Vdc Mechanical Life -- 106 KILOVAC High Voltage DC Contactors KILOVAC EV100 Series (Continued) Outline Dimensions 1.56 [39.6] Bottom Mount NOTE 1. MOUNTING HARDWARE (NOT SUPPLIED) 2 X M4 BOLT, LOCKWASHER AND WASHER TORQUE: 20 IN-LBS (2.3 NM) MAX NOTE 2 2.12 [53.8] .70 [17.8] 1.82 [46.2] NOTE 2. LOAD TERMINALS-2 PLCS HARDWARE NOT SUPPLIED 2 X M5 BOLT, LOCKWASHER AND WASHER TORQUE: 30-40 IN-LBS (3.4 TO 4.5 NM) DEPTH: 7 THREADS MAX .18 2 X (NOTE 1) [4.57] LEAD LENGTH 15" +/-.5" [381 +/-12.7] FROM TOP OF TERMINAL SEAT 1.77 [44.96] 1.53 [38.86] 1.71 [43.4] 1.49 [37.9] Coil Data (Internal Coil Economizer) Coil Voltage Range Maximum Pickup Current (20C) Average Holding Current (20C) Pickup Voltage (20C) Dropout Voltage Pickup Pulse (max.) Coil Resistance +/-5% (20C) Coil Economizer Frequency Coil Power Typ. (over temp range) 9-32 Vdc 1.5A 0.25A@12Vdc/0.15A@24Vdc 9Vdc 8Vdc 100 ms 8.0 19.6 kHz 3-4W .30 [7.62] 1.78 [45.2] Ordering Information Typical Part Number EV100 A A A N A Series: EV100 = 100A, 600 Vdc Contactor Contact Form: A = Normally Open Coil Voltage: 9-36 Vdc Coil Wire Length: A = 15 inches [.4M] Coil Termination: N = None - Stripped Wires Mounting: A = Bottom Mount 2X #8, M5X10 Mains Specifications are subject to change without notice. For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS KILOVAC High Voltage DC Contactors KILOVAC LEV100 Series 900 Vdc Contactor With 1 Form X Contacts Rated 100A Continuous Product Facts n Hermetically sealed -- Operates in explosive/ harsh environments without oxidation or contamination of contacts, including long periods of non-operation n 8kV isolation between open contacts permits use for high voltage isolation and carry n 12, 24 and 48 Vdc coils n Designed and built in accordance to AIAG QS9000 n Not position sensitive, can be mounted in any orientation n Solid copper contacts n UL Recognized for the U.S. and Canada (File E208033) All contact ratings & coil versions may not be UL Recognized n RoHS versions available Description Performance Data Lowest cost, 900 Vdc 100 amp, hermetically sealed DC contactor in the industry Physical Data Compact package available in side- or bottom-mount configurations, not position sensitive Applications Power/motor control circuit isolation, circuit protection and safety in industrial machinery Automotive battery switching and backup Mechanical Compact epoxy-sealed resin enclosure occupies only about 4 in3 (65.5 cm3) Inert gas filled contact chamber Flying leads for coil connections Load terminals threaded for M5 bolts (not included) Contact Data Contact Arrangement, Main Contacts -- SPST-NO-DM (1 Form X) Voltage Rating, Main Contacts Switching (Max) -- 900VDC Current Rating, Main Contacts Switching -- Continuous 1 -- 100A Short Term, 3 Minutes 2 -- 200A Hot Switching Performance (Polarity Sensitive) -- 50A make/break @ +400Vdc -- 50,000 cycles 100A make/break @ +400Vdc -- 6,000 cycles 100A make/break @ -400Vdc -- 1,000 cycles 200A make/break @ +400Vdc -- 500 cycles 1,000A break only @ +400Vdc -- 250 cycles 600A make only -- 25 cycles Maximum Short Circuit Current (1/2 cycle, 60 Hz) -- 1,250A (through closed contacts) Dielectric Withstand Voltage 3 -- Between Open Contacts -- 5,600Vrms/8,000Vdc Contacts to Coil -- 2,000Vrms/4,000Vdc Operate & Release Time Operate Time Max. -- 25ms Operate Bounce Max. -- 5ms Release Time -- 10ms Environmental Data Shock, 11ms 1/2 sine (operating) -- 20G peak Sine Vibration, 20G peak -- 55-2,000 Hz. Operating Temperature Range -- -40C to +85C Noise Emission (at 100 mm distance) -- 70dB(a) Notes 1 8.4 mm2 conductor. Current rating depends upon conductor size. Keep terminals below 175C max continuous. 2 3 minutes at +40C ambient with 8.4 mm2 (#8 AWG) conductor. 3 2,000Vrms minimum under all conditions, until end of life. For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. PAGE 43 7 KILOVAC High Voltage DC Contactors Robust integral mounting plate on either bottom or side of enclosure accepts two M4 screws Contact Arrangement, Main Contacts -- SPST-NO-DM (1 Form X) Dimensions -- See drawings on next page Weight -- 6.7 oz (190g) Insulation Resistance, Terminal to Terminal / Terminals to Coil -- When New -- 100 megohms, min. @ 500Vdc At End of Life -- 50 megohms, min. @ 500Vdc Mechanical Life -- 1 million cycles KILOVAC High Voltage DC Contactors KILOVAC LEV100 Series 900 Vdc Contactor (Continued) Coil Operating Voltage (Valid Over Temperature Range) Nominal Voltage 12Vdc 24Vdc Maximum Voltage 16Vdc 28Vdc Pick Up Voltage (20C) 8Vdc 16Vdc Drop Out Voltage (20C) 1.2Vdc 2.4Vdc Coil Current (Nominal at 20C, 12vdc) 461mA 250mA Coil Power Nominal @ Vnom, +20C 5.5W 6.0W Pickup (Close) Voltage Max.@85C 9.6Vdc 19.2Vdc Coil Resistance Nominal @ +20C 5% (ohms) 26 96 48Vdc 52Vdc 33Vdc 4.8Vdc 122mA 6.0W 38.4Vdc 392 Life Cycles vs Resistive Load up to 900Vdc Cycles (Make/Break) 1000000 100000 10000 1000 0 10 20 30 40 50 60 Resistive Load, kW 70 Ordering Information Typical Part Number LEV100 A 4 A N G Series: LEV100 = 100A Contactor Contact Arrangement: A = 1 Form X (SPST-NO-DM) Coil Voltage: 4 = 12VDC 5 = 24VDC 6 = 48VDC Coil Wire Length: A = 15 inches [.4M] Coil Termination: N = None - Stripped Wires For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Mounting and Power Terminals: G = Bottom Mount (2 x #8); M5 x 10 H = Side Mount (2 x #8); M5 x 10 AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS 80 90 KILOVAC High Voltage DC Contactors KILOVAC LEV100 Series 900 Vdc Contactor (Continued) Bottom Mount 1.82 [ 46.3 ] .70 [ 17.78 ] MOUNTING HARDWARE (NOT SUPPLIED): 2 X M4 BOLT, LOCKWASHER AND WASHER TORQUE: 20 IN-LBS MAX [2.3 NM MAX] M5 FEMALE LOAD TERMINALS - 2 PLACES HARDWARE (NOT SUPPLIED) 2 X M5 BOLT, LOCKWASHER AND WASHER TORQUE: 30 TO 40 IN-LBS [3.4 TO 4.5 NM] 1.56 DIA. [ 39.5 ] 2.28 [ 57.96 ] 2.07 [ 52.52 ] .30 [ 7.62 ] Side Mount 1.82 [ 46.32 ] 2.28 [ 57.96 ] .99 [ 25.04 ] MOUNTING HARDWARE (NOT SUPPLIED): 2 X M4 BOLT, LOCKWASHER AND WASHER TORQUE: 20 IN-LBS MAX [2.3 NM MAX] 2.07 [ 52.52 ] .70 [ 17.78 ] 1.56 DIA. [ 39.5 ] 1.61 [ 40.77 ] 7 .30 [ 7.62 ] Product Offering For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Bottom Mount Models 3-1618389-7 9-1618389-8 3-1618391-7 Side Mount Models 4-1618391-0 4-1618391-1 4-1618391-2 LEV100A4ANG LEV100A5ANG LEV100A6ANG 12Vdc coil 24Vdc coil 48Vdc coil 15" [.4m] leads 15" [.4m] leads 15" [.4m] leads LEV100A4ANH LEV100A5ANH LEV100A6ANH 12Vdc coil 24Vdc coil 48Vdc coil 15" [.4m] leads 15" [.4m] leads 15" [.4m] leads PAGE 45 KILOVAC High Voltage DC Contactors .83 [ 21.02 ] M5 FEMALE LOAD TERMINALS - 2 PLACES HARDWARE (NOT SUPPLIED) 2 X M5 BOLT, LOCKWASHER AND WASHER TORQUE: 30 TO 40 IN-LBS [3.4 TO 4.5 NM] KILOVAC High Voltage DC Contactors KILOVAC LEV100H High-Voltage Contactor Product Facts n Safe for application in harsh, explosive, and corrosive environments nNo contact oxidation over periods of non-use n Not position sensitive; available in side and bottom mount configurations n 8 kV isolation between open contacts permits use for high voltage isolation and carry n 12, 24, and 48 VDC coils available n Small 1000 VDC, 150 A contactor Applications n Energy Storage/Battery Storage n Power Distribution n Alternative Energy n Hybrid Electric Vehicles (Military and Commercial) n Test Equipment Description Mechanical/Environmental Electrical Data The new KILOVAC LEV100H extended performance contactors with auxiliary contacts from TE Connectivity (TE) are designed for harsh environment and load applications. This version of our popular EV and LEV series contactors offers extremely high performance for its small size and low weight. Hermetically sealed, KILOVAC LEV100H contactors are capable of operating in harsh, explosive environments without oxidation or contamination of contacts, even after long periods of non-operation. Contact Arrangement -- Mechanical Life -- 1,000,000 cycles Voltage Rating -- Main Contacts Switching (max.) -- 1000 VDC Continuous (Note 2) 100 A Short Term (3 minutes) (Note 3)-- 200 A Contact Voltage Drop -- Main Contacts: 0.05 max. @ rated current Resistive Load Performance (polarity sensitive) -- 50 A make/break @ +1000 VDC-- 50 cycles 100 A make/break @ +400 VDC-- 1000 cycles 200 A make/break @ +400 VDC-- 500 cycles 1000 A break only @ +400 VDC-- 2 cycles 600 A make only: 10 cycles 50 A @ 400 VDC make only-- 25,000 cycles Maximum Short Circuit Current (1/2 cycle, 60 Hz) (through closed contacts) -- 1250 A Dielectric Withstanding Voltage -- Between Open Contacts (Note 4) -- 5600 Vrms Contacts to Coil -- 2200 Vrms Insulation Resistance @ 500 VDC, Terminal to Terminal/ Terminals to Coil -- New -- 100 M min. End of Life -- 50 M min. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Main Contacts -- SPST-NO (Form X) Auxiliary Contact -- SPST-NO (Form A) (Note 1) Dimensions -- See drawings Weight -- 6.70 oz. (190 g) Hermetically Sealed Safe for Harsh/Corrosive Environments Contact Oxidation -- None over periods of non-use Shock -- 11 ms 1/2 sine (operating, 20 g Peak) Sine Vibration -- 20 g peak-- 55-2000 Hz Operating Temperature Range-- 40C to +80C Noise Emission (at 100 mm distance) -- 70 dBa KILOVAC High Voltage DC Contactors KILOVAC LEV100H High-Voltage Contactor (Continued) Operate and Release Time Coil Voltage, Nominal/Max. Coil Resistance (20C) Pick Up Voltage (20C) Dropout Voltage (20C) Coil Current (Nom. at 20C, 12 VDC) Coil Power (Nom. at Vnom, 20C) Operate Time (Max.) Main Operate Bounce (Max.) Contacts: Release Time Typical Part Number 12/16 VDC 24/28 VDC 48/52 VDC 26 8 VDC 1.2 VDC 0.46 A 5.5 96 16 VDC 2.4 VDC 0.25 A 6.0 25 ms 6 ms 10 ms 392 33 VDC 4.8 VDC 0.12 A 6.0 LEV100 H 5 C N G Series: LEV100 = 1000 VDC, 150 A Contactor Contact Form: H = NO with 1PST NO Aux Coil Voltage: 4 = 12 VDC 5 = 24 VDC 6 = 48 VDC Coil Wire Length: C = 10 [.25 m] Coil Termination: N = None - Stripped Wires Mounting : G = Bottom Mount, 2 x #8, M5 x 10 Mains Schematic H = Side Mount, 2 x #8, M5 x 10 Mains PART drawing +A1 (HVDC POWER) -A2 B1 B2 D 53.85 [2.12] 21.08 [.83] +X1 -X2 53.85 [2.12] 46.23 [1.82] 40.89 [1.61] (COIL) 17.78 [.70] O39.62 [O1.56] 17.78 [.701] 7 M5 FEMALE LOAD TERMINALS - 2 PLACES HARDWARE (NOT SUPPLIED) 2 X M5 BOLT, LOCKWASHER AND WASHER TORQUE: 30 TO 40 IN-LBS [3.4 TO 4.5 NM] C (AUXILIARY) KILOVAC High Voltage DC Contactors COIL LEADS: BLACK AUX LEADS: RED Note: Contactors should be installed so that current flows from A1 (+) to A2 (-) MOUNTING HARDWARE (NOT SUPPLIED) 2 X M4 BOLT, LOCKWASHER AND WASHER TORQUE: 20 IN-LBS MAX [2.3 NM MAX] 52.58 [2.07] LABEL B 52.58 [2.07] LABEL 25.15 [.99] 7.62 [.30] 46.23 [1.82] PAGE 47 KILOVAC High Voltage DC Contactors KILOVAC LEV200 Series Contactor With 1 Form X Contacts Rated 500+ Amps, 12-900Vdc Product Facts n Designed to be the lowest cost sealed contactor in the industry with its current rating (500+A carry, 2000A interrupt at 320Vdc) n Available with bottom or side mounting -- not position sensitive n Optional auxiliary contact for easy monitoring of power contact position n Hermetically sealed -- operates in explosive/ harsh environments with no oxidation or contamination of coils or contacts, including long periods of non-operation Performance Data Coil Data (Valid Over Temperature Range) 4 Nominal Voltage 12Vdc 24Vdc Pickup Voltage (Will Operate) 9.0Vdc 19.0Vdc Voltage (Max.) 15Vdc 30Vdc Dropout Voltage 0.75 - 2.0Vdc 1.0 - 5.0Vdc Coil Resistance @ 25 (Typ.) 11 ohms 40 ohms Typical applications include battery switching and backup, DC voltage power control, circuit protection and safety Ordering Information n Versatile coil/power connections n Designed and built in accordance to AIAG QS9000 Series: LEV200 = 500+ Amp, 12-900Vdc Contactor n RoHS compliant n Typical Part Number 48Vdc 38.0Vdc 60Vdc 2.0 - 7.0Vdc 145 ohms LEV200 A 4 N A A Contact Form: A = Normally Open H = Normally Open with Aux. Contacts. (Option "H" requires option "A" in Coil Wire Length and option "N" in Coil Terminal Connector.) Note: Other auxiliary contact forms available. Consult factory. Coil Voltage: 4 = 12Vdc 5 = 24Vdc B = 28Vdc 6 = 48Vdc K = 72Vdc 8 = 96Vdc L = 110Vdc O = 115Vac 9 = 240Vac Notes: Consult factory for detailed specifications and availability of coils not listed in "Coil Data" table above. In coil voltage codes, 115Vac is designated by the letter "O" rather than the numeral "0." Coil Wire Length: A = 15.3 in (390 mm) N = None (Requires option "A" in next step.) Coil Terminal Connector: N = None, stripped wires (Requires option "A" in previous step.) A=S tuds, #10-32 Threaded (Electrical connection is made to the tab at the base of the stud.) Note: Specify option A, stripped wires, for coil voltages > 96Vdc For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Mounting & Power Terminals: A = Bottom Mount & Male 10mm x M8 Threaded Terminals F = Side Mount & Male 10mm x M8 Threaded Terminals Consult factory regarding other available mountings and power terminals. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Contact Arrangement, Power Contacts -- 1 Form X (SPST-NO-DM) Rated Operating Voltage -- 12 - 900 VDC Continuous (Carry) Current, Typical -- 500 A @ 65C, 400 mcm conductors Consult TE for required conductors for higher (500+ A) currents Make/Break Current at Various Voltages 1 -- See graph next page Break Current at 320VDC 1 -- 2,000 A, 1 cycle 3 Contact Resistance, Typ. (@200A) -- 0.2 mohms Load Life -- See graph next page Mechanical Life -- 1 million cycles Contact Arrangement, Auxiliary Contacts -- 1 Form A (SPST-NO) Aux. Contact Current, Max. -- 2A @ 30VDC / 3A @ 125VAC Aux. Contact Current, Min. -- 100mA @ 8V Aux. Contact Resistance, Max. -- 0.417 ohms @ 30VDC / .150 ohms @ 125VAC Operate Time @ 25C -- Close (includes bounce), Typ. -- 25 ms Bounce (after close only), Max. -- 7 ms Release (includes arcing), Max @ 2000A -- 12 ms Dielectric Withstanding Voltage -- 2,200 Vrms @ sea level (leakage <1mA) Insulation Resistance @ 500VDC -- 100 megohms 2 Shock, 11ms 1/2 Sine, Peak, Operating -- 20 G Vibration, Sine, 80-2000Hz., Peak -- 20 G Operating Ambient Temperature -- -40C to +85C Weight, Typical -- 1.3 lb. (.60 kg) Notes: 1 Main power contacts 2 50 at end of life 3 Does not meet dielectric & IR after test, 1700 amp for unit with Aux. Contacts 4 Contacts will operate with 0.8Vnom < Vcoil < 1.1Vnom over temperature Invalid Combinations/Reason LEV200H-NA_ No auxiliary function with coil studs LEV200_ONA_ No coil studs with rectifier circuit LEV200_9NA_ No coil studs with rectifier circuit LEV200_O_F No side mont with rectifier circuit LEV200_9_F No side mount with rectifier circuit KILOVAC High Voltage DC Contactors KILOVAC LEV200 Series (Continued) Outline Dimensions Note: When stud terminals are specified for coil connections, the electrical connection is made at the tab located at the base of the stud. SIde Mount Enclosure Bottom Mount Enclosure Estimated Make & Break Power Switching Ratings 650A Break Only Above 650A Make and Break Power Switching Region 100,000 LEV200 Capacitive Make Test Curves for Pre-Charged Motor Controller 700 650 600 10,000 80% Minimum Pre Charge 500 450 120 VDC C VD VDC Current (A) 900 100 400 400 90% Nominal Pre Charge 350 7 300 250 200 150 10 100 50 1 1 10 100 Load Current (A) 1,000 10,000 0 0.0 0.5 1.0 Time (ms) 1.5 2.0 NOTES: 1) For resistive loads with 300H maximum inductance. Consult factory for inductive loads. 2) Estimates based on extrapolated data. User is encouraged to confirm performance in application. 3) End of life when dielectric strength between terminals falls below 50 megohms @ 500VDC. 4) The maximum make current is 650A to avoid contact welding. For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. PAGE 49 KILOVAC High Voltage DC Contactors Estimated Life (Cycles) 28 VDC C VD VDC 270 600 DC 0V 180 1,000 550 KILOVAC High Voltage AC Contactors FM200 ("Flatman III") Series Contactor 200 Amps, 480 VAC (50/60 Hz), or 48 Vdc, 1-, 2-, or 3-poles Product Facts n Multi-pole configurations n Normally open, normally closed and mixed contact arrangements n Optional quick connect tabs for sensing n Small, lightweight & costeffective - designed to be the smallest, lowest cost contactor in the industry with its current rating n Standard models available with 12VDC, 24VDC and 115 VAC coils. Consult factory for 240VAC coil models. n 1 Form A auxiliary contacts For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. File E208033 Product Specifications Value for FM200 Series Coil Operating Voltage (valid over temperature range) Contact Arrangement 1, 2 or 3 poles Coil Designator Units A B C D Contact Form (per pole) Form X or Y (NO-DM or NC-DB) Nominal Voltage V 12 (DC) 24 (DC) 115 (AC) 24 (DC) Rated Operating Voltage V 480Vrms (L-L) or 48VDC Max. Contact Voltage (transient) V 750Vrms or 60VDC Voltage Range 26.4 V 9.6-13.2 19.2-26.4 92-126.5 19.2- Continuous (Carry) Current Arms or ADC 200/pole (Form X) 150/pole (Form Y) Hold Voltage V 0.5Vnom 0.5Vnom 0.5Vnom 0.5Vnom Power Switching Form X (0.7-1.0 PF) Cycles Dropout Voltage V 0.1Vnom 0.1Vnom 0.1Vnom 0.2Vnom Coil Resistance Data for Pole Configurations (@25C) Parameter Units 2,000 @ 300Arms 10,000@ 200Arms 20,000 @ 100Arms 5,000 @ 200A/48VDC 2 million @ 50A/28VDC Coil Designator Units A B* C* D* X = 36 XX = 18 XXX = 12 XY = 13.2 XYX = 9.6 X = 36 XX = 18 XXX = 12 XY = 13.2 XYX = 9.6 X = 36 XX = 18 XXX = 12 XY = 13.2 XYX = 9.6 Y = 20.8 YY = 10.4 YYY = 6.9 YXY = 8.1 Power Switching Form Y (0.7-1.0 PF) Cycles 2,000 @ 225Arms 10,000@ 150Arms 20,000 @ 75Arms 5,000 @ 150A/48VDC 2 million @ 35A/28VDC Resistance 10% Ohms Mechanical Life >2 million *Coil resistance not measurable at terminals due to converter/economizer circuit. Contact Voltage Drop Cycles mV Auxiliary Contact Arrangement Auxiliary Contact Rating Dielectric Withstanding Voltage Insulation Resistance @ 500VDC 75 for Form X or Form Y 1 Form A (SPST-NO) Vrms 2,200 @ sea level Megohms 100 Shock, 11ms 1/2 sine, peak G 10 Vibration, sine, 10-2000Hz. G 5 Operating Temperature C -20 to +60 Storage Temperature C -40 to +85 Ambient Humidity Coil Current/Power Data for Pole Configurations (@25C, Vcoil=1.1Vnom) Arms or ADC 1 @ 30VDC, 3 @ 125VAC %RH Coil Designator A B** Current/Power X = 0.37 ADC / 4.84W XX = 0.73ADC / 9.68W XXX = 1.1ADC / 14.5W XY = 1.0ADC / 13.2W XYX = 1.38ADC / 18.2W X = 0.33ADC / 3.9W XX = 0.65ADC / 7.6W XXX = 0.97ADC / 11.3W XY = 0.98ADC / 12.7W XYX = 1.31ADC / 16.5W Coil Designator Current/Power 0 to 95 Weight oz. / kg 17.6 - 49.4 / 0.5 -1.4 See Outline Dimensions for model-specific weight information. **Average coil current. Available Pole Configurations and Applicable Coil Codes No. of NC Poles (across) 0 1 No. of NO Poles (down) 0 Y Coil D 1 X XY Coil A/B/C/E Coil A/B/C/E 2 XX XYX Coil A/B/C/E Coil A/B/C/E 3 XXX Coil A/B/C/E X = Form X (NO-DM) Y = Form Y (NC-DB) C 2 3 YY Coil D YXY Coil D YYY Coil D AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS D*** Pick-Up I / Duration X = 0.067 Arms / 6.8VA Y = 0.13ADC / 3.4W XX = 0.115Arms / 11.6VA YY = 0.23ADC / 6.1W XXX = 0.146Arms / 14.8VA YYY = 0.34ADC / 9.0W XY = 0.074Arms / 7.5VA YXY = 0.28ADC / 7.4W XYX = 0.161Arms / 16.3VA 1.28ADC / 75ms 2.4ADC / 75ms 3.0ADC / 75ms 3.0ADC / 75ms ***Economized. Operate/Release Time (25C, 0.8Vnom V < Vnom) Typ. Coil Designator Units A B**** C**** D**** Operate Time ms 25-50 30-50 50-150 20-30 Release Time ms 10-20 70-80 75-100 75-100 Bounce Time ms 2-5 2-5 2-5 2-5 ****Includes internal coil suppression. KILOVAC High Voltage AC Contactors FM200 "Flatman III" Series Contactor (Continued) Part Numbering System Typical Part Number FM200 A B XYX Series: FM200 = Multipole, 200 Amp, 480VAC/48VDC Contactor Control Voltage: A = 12VDC Coil, No Suppression B = 24VDC Converter, with Suppression C = 115VAC Converter, with Suppression D = 24VDC Electronic Chopper, with Suppression E = 240VAC Converter, with Suppression - Consult Factory for Availability and Specifications Optional Termination: A = Optional Quick Connect Tabs B = No Optional Terminals Pole Configuration (All models have a 1 Form A (SPST-NO) auxiliary switch): X = 1 Form X (SPST-NO-DM), Available with control voltage codes A, B, C and E XX = 2 Form X (2PST-NO-DM), Available with control voltage codes A, B, C and E XXX = 3 Form X (3PST-NO-DM), Available with control voltage codes A, B, C and E Y = 1 Form Y (SPST-NC-DB), Available only with control voltage code D YY = 2 Form Y (DPST-NC-DB), Available only with control voltage code D YYY = 3 Form Y (3PST-NC-DB), Available only with control voltage code D XY = 1 Form X (SPST-NO-DM) + 1 Form Y (SPST-NC-DB), Available with control voltage codes A, B, C and E XYX = 1 Form X (SPST-NO-DM) + 1 Form Y (SPST-NC-DB) + 1 Form X (SPST-NO-DM), Available with control voltage codes A, B, C and E YXY = 1 Form Y (SPST-NC-DB) + 1 Form X (SPST-NO-DM) + 1 Form Y (SPST-NC-DB), Available only with control voltage code D Outline Dimensions 2 .29 (58 .2) 1 .86 (47 .2) OPTIONAL TAB TERMINALS .250 x .032 (6 .35 x .813) .40 (10 .2) C MAIN TERMINAL WIRE CONNECT VIA M8 BOLT W/LOCK/FLAT 13MM (0 .5 IN) HEX HEAD 3 .77 (95 .8) 2 .29 (58 .2) 1 .93 (49 .0) 1 .22 (31 .0) 4 .2 (106 .7) NUMBER OF POLES 1 1 .68 (42 .7) 2 2 .67 (67 .7) 3 3 .65 (92 .7) B 2 .14 (54 .3) 3 .12 (79 .3) 4 .11 (104 .4) C 1 .56 (39 .6) 2 .55 (64 .6) 3 .53 (89 .7) WEIGHT 17 .6 oz . (0 .5 kg) 35 .3 oz . (1 .0 kg) 49 .4 oz . (1 .4 kg) A 3 .42 (86 .9) 3 .77 (95 .8) 7 RIGHT ANGLE SCREW TERMINAL STRIP ACCEPTS #24 - #14 WIRE KILOVAC High Voltage AC Contactors DIM. A 2 .74 (69 .6) 2 .98 (75 .7) B .256 DIA . (6 .5) For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. PAGE 51 KILOVAC 270+ Vdc Traditional Aerospace Contactors AP90X-05 - 90 Amps SPUD Contactor Product Facts n 90 A carry, 350 A overload @ 270 Vdc n Same size and weight as AP50X n Versatile power, voltage, and current operating range n Ideal for circuit protection and control n Bi-directional switching n Fast operate and release time n Low power consumption n Vacuum-sealed contacts; can operate in harsh environments n Space-rated version built in accordance with customers SCD n Meets many requirements of MIL-PRF-32085 Contact Ratings* *Based on data extrapolated from qualification at 270 Vdc with resistive load. Since each application is unique, user is encouraged to verify rating in actual application. Product Specifications Contact Arrangement -- SPST-NO Contact Form -- X Rated Resistive Load @ 270 Vdc -- 90 A Continuous Current Carry, Max. -- 65 A Overload @ 270 Vdc -- 350 A Contact Resistance, Max. -- 2 mohm Dielectric at Sea Level -- Coil to Power Terminals -- 1,800 Vrms All Other Points -- 2,000 Vrms Shock, 11ms, 1/2 Sine (Peak) -- 30 g Vibration, Sinusoidal (55-2000 Hz, Peak) -- 20 g Operating Ambient Temperature Range -- -55C to +90C Load Life @ 270 Vdc, Min. -- 25,000 cycles Coil Data Volts, Nominal 12 28 120 Pickup, Max. 9.9 Vdc 23 Vdc 99 Vdc Dropout, Min..4 Vdc 1.0 Vdc 4.0 Vdc Coil Resistance (10%) 19 103 1890 Energy, Magnetic, Max..05 J.05 J.05 J Coil resistance rated at 25C For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Operate Time, Excluding Bounce, Max. -- 35 ms Release Time, Max. -- 10 ms Bounce Time, Max. -- 8 ms Insulation Resistance @ 500 Vdc, Min. -- Initial -- 100 mohm End of Life -- 50 mohm Weight, Nominal -- 454 gram (16 oz.) KILOVAC 270+ Vdc Traditional Aerospace Contactors AP90X - 90 Amps SPUD Contactor Product Facts n 90 A carry, 350 A overload @ 270 Vdc n Same size and weight as AP50X n Versatile power, voltage, and current operating range n Ideal for circuit protection and control n Bi-directional switching n Fast operate and release time n Low power consumption n Vacuum-sealed contacts; can operate in harsh environments n Space-rated version built in accordance with customers SCD n Meets many requirements of MIL-PRF-32085 Contact Ratings* *Based on data extrapolated from qualification at 270 Vdc with resistive load. Since each application is unique, user is encouraged to verify rating in actual application. Product Specifications Contact Arrangement -- SPST-NO Contact Form -- X Rated Resistive Load @ 270 Vdc -- 90 A Continuous Current Carry, Max. -- 90 A Overload @ 270 Vdc -- 350 A Contact Resistance, Max. -- 2 mohm Volts, Nominal 12 28 120 Pickup, Max. 9.9 Vdc 23 Vdc 99 Vdc Dropout, Min..4 Vdc 1.0 Vdc 4.0 Vdc Coil Resistance (10%) 19 103 1890 Energy, Magnetic, Max..05 J.05 J.05 J Coil resistance rated at 25C Operate Time, Excluding Bounce, Max. -- 27 ms Release Time, Max. -- 10 ms Bounce Time, Max. -- 8 ms Insulation Resistance @ 500 Vdc, Min. -- Initial -- 100 mohm End of Life -- 50 mohm Weight, Nominal -- 454 gram (16 oz.) Ordering Information Sample Part Number AP90 X B 5 7 Series: Contact Form: X = SPST-NO Double Make Coil Voltage: A = 12 Vdc, Stud Terminals B = 28 Vdc, Stud Terminals C = 120 Vdc, Stud Terminals For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Power Terminals: 5 = Stud Terminals Mounting: 7 = Panel Mount PAGE 53 7 KILOVAC 270+ Vdc Traditional Contactors Coil Data Dielectric at Sea Level -- Coil to Power Terminals -- 1,800 Vrms All Other Points -- 2,000 Vrms Shock, 11ms, 1/2 Sine (Peak) -- 30 g Vibration, Sinusoidal (55-2000 Hz, Peak) -- 20 g Operating Ambient Temperature Range -- -55C to +85C Load Life @ 270 Vdc, Min. -- 25,000 cycles KILOVAC 270+ Vdc Traditional Aerospace Contactors AP150X (Form X, Electrically Held) CZONKA Contactor Product Facts n 150 A carry, 500 A overload @ 270 Vdc n Suitable for circuit protection, control, and battery switching n Versatile power, voltage, and current operating range n Bi-directional switching n Electrically held and latching coil versions n Fast operate and release time n Low power consumption n Vacuum-sealed contacts; can operate in harsh environments n Space-rated version built in accordance with customers SCD n Meets many requirements of MIL-PRF-32085 Contact Ratings* Product Specifications Contact Arrangement -- AP150X -- SPST-NO Contact Form -- AP150X -- X Rated Resistive Load @ 270 Vdc -- 150 A Continuous Current Carry, Max. -- 150 A Overload Make & Break @ 270 Vdc -- 400/500 A* Contact Resistance, Max. -- 1 mohm Dielectric at Sea Level -- Power Terminals to Terminal -- 2,000 Vrms Power Terminals to All Other Points -- 1,800 Vrms Shock, 11ms, 1/2 Sine (Peak) -- 35 g Vibration, Sinusoidal (55-2000 Hz, Peak) -- 20 g Operating Ambient Temperature Range -- -55C to +85C Load Life @ 270 Vdc, Min. -- 10,000 cycles Operate Time (28 Vdc, 25C) -- Close (Includes Bounce), Typ. -- AP150X -- 35 ms Bounce (After Close Only), Max. -- AP150X -- 8 ms Open (Includes Arcing), Max. -- AP150X -- 10 ms Insulation Resistance @ 500 Vdc, Min. -- Initial/End of Life -- 100 mohm/50 mohm Weight, Nominal -- 1.66 lb (0.753 kg) Note: *500 = at beginning of life which is 0 to 5,000 cycles, 400 = at end of life which is 5,000 to 10,000 cycles. For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS *Based on data extrapolated from qualification at 270 Vdc with resistive load. Since each application is unique, user is encouraged to verify rating in actual application. Coil Data Voltage, Nominal* Pickup (Close), Max. Dropout (Open), Max. Coil Resistance @ 25C (10%) Coil Duty, Recommended Coil Energy, Max. Coil Clamping AP150X 28 Vdc 23 Vdc 1.0 Vdc 52 Continuous 0.10 J 2.5 x nom. AP150P 28 Vdc 20 Vdc 20 Vdc 13 ** 100 ms to Toggle 0.10 J 500W/ms TVS *12, 120 Vdc, or other special coil voltages available upon request. **2 coils are used, both are high common. Switch coil power from low side. High side coil power switch is a special order. Ordering Information Sample Part Number Series: Contact Form: X = SPST-NO Electrically Held Coil Voltage: A = 12 Vdc, Stud Terminals, .138-32 B = 28 Vdc, Stud Terminals, .138-32 C = 120 Vdc, Stud Terminals, .138-32 Power Terminals: 5 = Stud Terminals, .375-24 Mounting: 7 = Panel Mount AP150 X B 5 7 KILOVAC 270+ Vdc Traditional Aerospace Contactors AP265 (Form X, Electrically Held) & AP265P (Form P, Latching) 265 Amps CZONKA II Contactor Product Facts n 265 A carry, 1000 A overload @ 270 Vdc n Bi-directional power switching n Auxiliary Contacts n Electrically held and latching coil versions n Built-in coil drivers for electrically held (5W hold) and latching (coil pulser) n Coil divers EMC qualified to most of the requirements of MIL-STD-461D n Versatile power, voltage, and current operating range n Excellent for safety disconnect and transfer switch applications n Designed for main generator loads n Suitable for circuit protection and control n Remote Power Controller version with overload protection available -- contact factory for more information n Hermetically-sealed contacts; can operate in harsh environments n Space-rated version built in accordance with customers SCD n Meets many requirements of MIL-PRF-32085 Product Specifications Contact Arrangement Mains -- AP265X -- Form X -- SPST-NO Form A -- 2 x SPST-NO AP265P -- Form X -- SPST Form A -- 2 x SPST Polarity (Carry and Switching) -- Bi-directional Rated Resistive Load @ 270 Vdc -- 265 A Continuous Current Carry, Max. -- 265 A Overload Current @ 270 Vdc, Max. -- Make and Break -- 600 A Break Only -- 1000 A Contact Resistance, Max. -- 0.3 mohm Dielectric at Sea Level (< 1 mA leakage) -- Power Terminals to Terminal -- 1,000 Vrms Power Terminals to All Other Points -- 1,000 Vrms Shock, 11ms, 1/2 Sine (Peak) -- 25 g Vibration, Sinusoidal (55-2000 Hz, Peak) -- 10 g Operating Ambient Temperature Range -- -55C to +85C Load Life @ 270 Vdc, Min. -- See graph above Operate Time (28 Vdc, 25C) -- Close (Includes Bounce), Typ. -- AP265X -- 20 ms AP265P -- 10 ms Bounce (After Close Only), Max. -- 5 ms Open (Includes Arcing), Max. -- 15 ms Insulation Resistance @ 500 Vdc, Min. -- Initial/End of Life -- 100 mohm/50 mohm Weight, Nominal -- 1.7 lb (0.77 kg) Coil Data Type Driver Voltage, Nominal Pickup (Close), Max. Dropout (Open), Max. Current @ 28 V, 25C Inrush Holding (Standby) Inrush Time, Max. AP265X "PWM" Econ. 28 Vdc 20 Vdc 11 Vdc AP265P Pulser 28 Vdc 12 Vdc 12 Vdc 1.8 A 0.20 A 100 ms 2.6 A <0.05 A 100 ms 7 Ordering Information Sample Part Number AP265 X E 9 7 Series: Contact Form: X = SPST-NO, Electrically Held P = SPST, Latching Coil Voltage: E = 28 Vdc Power Terminals: 9 = Female Threads, .250-20 Mounting: 7 = Panel Mount, Helcoil Locking PAGE 55 KILOVAC 270+ Vdc Traditional Contactors For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Electrical Life Cycles vs Power Switching KILOVAC 270+ Vdc Traditional Aerospace Contactors AP350X "BUBBA" Contactor 500 Amps Product Facts n 500 A carry, 1200 A make, 3000 A break @ 270 Vdc n Bi-directional power switching n Auxiliary Contacts n Built-in coil power economizing -- 6 W holding n Versatile power, voltage, and current operating range n Excellent for safety disconnect and transfer switch applications n Suited for circuit protection control n Hermetically-sealed contacts; can operate in harsh environments n Designed for main generator loads n Space-rated version built in accordance with customers SCD n Meets many requirements of MIL-PRF-32085 Coil Data AP350X Type Driver "PWM" Econ. Voltage, Nominal 28 Vdc Pickup (Close), Max. 20 Vdc Dropout (Open), Max. 11 Vdc Current @ 28 V, 25C Inrush 2.1 A Holding (Standby) 0.21 A Inrush Time, Max. 200 ms Product Specifications Contact Arrangement with Auxiliary Contact (28 Vdc, 0.1 A) -- Form X -- SPST-NO Form A -- SPST-NO Rated Resistive Load @ 270 Vdc, 85C -- 350 A Continuous Current Carry, Max., 25C -- 500 A Overload Current @ 270 Vdc, Max. -- Make (Closed Into) -- 1200 A Break (Open) -- 3000 A Contact Resistance, Max. -- 0.2 mohm Dielectric at Sea Level (< 1mA leakage) -- Open Power Terminal to Terminal -- 2,000 Vrms Closed Power Terminals to All Other Points -- 2,000 Vrms Shock, 11ms, 1/2 Sine (Peak) -- 25 g Vibration, Sinusoidal (55-2000 Hz, Peak) -- 10 g Operating Ambient Temperature Range -- -55C to +85C Load Life @ 270 Vdc, Min. -- See graph above Operate Time @ 25C -- Close (Includes Bounce), Typ. -- 35 ms Bounce (Occurs When Closing), Max. -- 5 ms Open (Includes Arcing), Max. -- 20 ms Insulation Resistance @ 500 Vdc, Min. -- Initial/End of Life -- 100 mohm/50 mohm Weight, Nominal -- 3.35 lb (1.52 kg) For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Electrical Life Cycles vs Power Switching *Failure mode: Dielectric withstand voltage test @ 2000 Vdc, power terminal to terminal, leakage exceeds 1.0 A. Current Carry: 500 A @ 25C. Derate 2.5 A/C to 350 A @ 85C for still air, no heat sink, AWG# 00 conductor. Ordering Information Sample Part Number AP350 X B 5 7 Series: Contact Form: X = SPST-NO Double Make Coil Voltage: B = 28 Vdc, Stud Terminals Power Terminals: 5 = Screw Terminals Mounting: 7 = Panel Mount, captive bolts Refer to EV500 Sales Drawing for complete specifications. KILOVAC 28 - 1800 Vdc Traditional Contactors EV250-1A & 1B 400 Amps CZONKA-II EVX Make & Break Load Switching Product Facts n Hydrogen dielectric for power switching high current loads n 400 A carry, 2,500 A interrupt @ 320 Vdc n Suited for circuit protection, control, battery switching, and main power safety disconnect n Versatile power, voltage, and current operating range: 28-1800 Vdc tested n Low-cost compact version for volume production applications. Requires external coil economizer (PWM or lower hold voltage) n "Hammer effect" mechanism breaks light contact welds n "Super-sealed" environment chamber uniquely protects ALL moving parts n Can operate in harsh environments n Moving contact rotates to provide fresh contact surface for low contact resistance and low power consumption Sealed control connector. Mating connector with flying leads Part Number 2005 available, see page 7-95 n Logic control enabled by external economizer Part Number 9913 n High temperature (135C) model with 10 inch flying leads available (-4A -- Call TE for sales drawing) n Bi-directional power switching n Fast operate and release time Product Specifications Contact Arrangement -- SPST-NO Contact Form -- X Continuous Current Carry, Max. -- 400 A; 6.5 Minutes -- 500 A Break Current @ 320 Vdc -- 2,500 A Contact Resistance, Max. -- 0.0003 ohm Contact Resistance, Typ. -- 0.0001 - 0.0002 ohm Dielectric at Sea Level (Leakage < 1mA) -- 2,200 Vrms Shock, 11ms, 1/2 Sine (Peak), Operating -- 30 g Vibration, Sinusoidal (80-2000 Hz, Peak) -- 20 g Operating Ambient Temperature Range -- -40C to +85C Load Life -- See chart on next page Operate Time, @ 25C -- Close (Includes Bounce), Typ. -- 30 ms Bounce (After Close Only), Max. -- 5 ms Open (Includes Arcing), Max. -- 15 ms Insulation Resistance @ 500 Vdc, Min. -- 100 mohm Weight, Nominal -- 1.54 lb (0.7 kg) Contact Ratings* *For circuit conditions and actual data refer to the EV250 hot switch study. Since each application is unique, user is encouraged to verify rating in actual application. Coil Data*** Voltage, Nominal* Pickup (Close), Max. Continuous Hold, Max./Min.** Dropout (Open), Min. Coil Resistance @ 25C, 10% Coil Energy, Max. Coil Clamping EV250-1A 12 Vdc 8.3 Vdc 5.1/3.8 Vdc 0.88 - 3.3 Vdc 3 0.2 J 3 x nom. EV250-1B 24 Vdc 16.6 Vdc 10.2/7.6 Vdc 2.4 - 6.6 Vdc 12 0.2 J 3 x nom. *Do not apply continuously. Requires external coil economizer. Other special coil voltages available upon request. **At maximum continuous current and maximum ambient temperature. Hold voltage must be maintained within the limits specified to keep contacts closed and to prevent coil overheating. ***Do not use a free wheeling diode or capacitor across the coil. Ordering Information Sample Part Number EV250-1 A Series: Coil Voltage: A = 12 Vdc, Nominal B = 24 Vdc, Nominal For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. For detailed specifications and recommendations, refer to the EV250-1A & B sales drawings. PAGE 57 7 KILOVAC 28 - 1800 Vdc Traditional Contactors n Note: Dimensions in inches. Multiply values by 25.4 for dimensions in mm. KILOVAC 28 - 1800 Vdc Traditional Contactors EV250-1A & 1B 400 Amps CZONKA-II EVX Make & Break Load Switching (Continued) Current vs Time Life Ratings and Qualification Test Plan Normal Operations Abnormal Operations Test # 1 2 3 Current -250 A Reference Graph and Test Circuit Diagram (Sht. 8) Voltage 320 V Load Type Capacitive Capacitive Resistive % Pre Charge 90% 70% NA Switch Mode Make Only Make Only Make/Break Sequence 1 10K cycles 10 cycles 2 2 10K 10 2 3 10K 10 2 4 10K 10 2 5 10K 10 2 Etc. Continue Cycling to Relay Failure 4 2500 A 320 V Resistive N/A Break Only 2 -- -- 2 -- The testing objective is to verify proper relay function for a given number of consecutive and cumulative cycles under both normal and abnormal conditions in a variety of load switching applications. The life rating of 40K cycles minimum was calculated with 95% Weibull reliability. Electrical Data (Over Temperature Range -- Max. Terminal Temp. = 200C) For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Make/Break Life for Capacitive & Resistive Loads at 320 Vdc 1,2 -- @ 90% Capacitive Pre-Charge -- 50,000 cycles @ 70% Capacitive Pre-Charge -- 50 cycles @ -250 A (2 Consecutive, Reverse Polarity) 1 -- 10 cycles @ 3300 A (Break only, 2 Consecutive) 1 -- 4 cycles Mechanical Life -- 100,000 cycles AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Notes: 1 Resistive load includes inductance L = 25 H. Load @ 2500 A tested @ 200 H. 2 Conductor: 2 each of copper 54 mm2 (AWG 0) required for > 250 A carry. 1 Copper (AWG 0) conductor recommended for 250 A KILOVAC 28 - 1800 Vdc Traditional Contactors EV250-2A & 2B 400 Amps CZONKA II EVX Make & Break Load Switching Product Facts n Hydrogen dielectric for power switching high current loads n 400 A carry, 2,500 A interrupt @ 320 Vdc n Suited for circuit protection, control, battery switching, and main power safety disconnect n Versatile power, voltage, and current operating range: 28-1800 Vdc tested n Internal coil economizer provides: n4W typical hold power independent of temperature & voltage range nEMI spectrum tested and approved nBuilt-in coil suppression n "Hammer effect" mechanism breaks light contact welds n Hermetically "Super-sealed" environment chamber uniquely protects ALL moving parts n Can operate in harsh environments n Moving contact rotates to provide fresh contact surface for low contact resistance and low power consumption Sealed control connector. Mating connector with flying leads Part Number 2005 available n Special versions available: nEconomical (-8A/B) for light duty power switching (without arc blowout magnets) n10 inch flying leads model (-7A) Product Specifications Contact Ratings* Contact Arrangement -- SPST-NO Contact Form -- X Continuous Current Carry, Max. -- 400 A; 6.5 Minutes -- 500 A Break Current @ 320 Vdc -- 2,500 A Contact Resistance, Max. -- 0.0003 ohm Contact Resistance, Typ. -- 0.0001 - 0.0002 ohm Dielectric at Sea Level (Leakage < 1mA) -- 2,200 Vrms Shock, 11ms, 1/2 Sine (Peak), Operating -- 30 g Vibration, Sinusoidal (80-2000 Hz, Peak) -- 20 g Operating Ambient Temperature Range -- -40C to +85C Load Life -- See chart on next page Operate Time, @ 25C -- Close (Includes Bounce), Typ. -- 18 ms Bounce (After Close Only), Max. -- 5 ms Release Time (Includes Arcing), Max. -- 15 ms Insulation Resistance @ 500 Vdc, Min. -- 100 mohm Weight, Nominal -- 1.76 lb (0.8 kg) *For circuit conditions and actual data refer to the EV250 hot switch study. Since each application is unique, user is encouraged to verify rating in actual application. Coil Data** Voltage, Nominal* Pickup (Close), Max. Hold, Min. Dropout (Open), Min. Current (@ VsNom / 25C) Inrush Holding, Standby Inrush Time, Max. EV250-2A 12 Vdc 9 Vdc 7 Vdc 5 Vdc EV250-2B 24 Vdc 18 Vdc 14 Vdc 10 Vdc 2.8 A 0.34 A 200 ms 1.8 A 0.11 A 200 ms 7 *Other special coil voltages available upon request. **Do not use a free wheeling diode or capacitor across the coil. Built in suppression limits back EMF to zero volts. Ordering Information Sample Part Number EV250 -2 A Series: Model: 2 = With Blowout Magnets 8 = Without Blowout Magnets 7 = 10" Flying Leads (12 V, with Magnets Only) For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Coil Voltage: A = 12 Vdc, Nominal B = 24 Vdc, Nominal For detailed specifications and recommendations, refer to the EV250-2A & B or 7A sales drawings. PAGE 59 KILOVAC 28 - 1800 Vdc Traditional Contactors n Note: Dimensions in inches. Multiply values by 25.4 for dimensions in mm. KILOVAC 28 - 1800 Vdc Traditional Contactors EV250-2A & 2B 400 Amps CZONKA II EVX Make & Break Load Switching (Continued) Life Ratings and Qualification Test Plan Normal Operations Abnormal Operations Test # 1 2 3 Current -250 A Reference Graph and Test Circuit Diagram (Sht. 8) Voltage 320 V Load Type Capacitive Capacitive Resistive % Pre Charge 90% 70% NA Switch Mode Make Only Make Only Make/Break Sequence 1 10K cycles 10 cycles 2 2 10K 10 2 3 10K 10 2 4 10K 10 2 5 10K 10 2 Etc. Continue Cycling to Relay Failure 4 2500 A 320 V Resistive N/A Break Only 2 -- -- 2 -- The testing objective is to verify proper relay function for a given number of consecutive and cumulative cycles under both normal and abnormal conditions in a variety of load switching applications. The life rating of 40K cycles minimum was calculated with 95% Weibull reliability. Electrical Data (Over Temperature Range -- Max. Terminal Temp. = 200C) For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Make/Break Life for Capacitive & Resistive Loads at 320 Vdc 1,2 -- @ 90% Capacitive Pre-Charge -- 50,000 cycles @ 70% Capacitive Pre-Charge -- 50 cycles @ -250 A (2 Consecutive, Reverse Polarity) 1 -- 10 cycles @ 3300 A (Break only, 2 Consecutive) 1 -- 4 cycles Mechanical Life -- 100,000 cycles AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Notes: 1 Resistive load includes inductance L = 25 H. Load @ 2500 A tested @ 200 H. 2 Conductor: 2 each of copper 54 mm2 (AWG 0) required for > 250 A carry. 1 Copper (AWG 0) conductor recommended for 250 A KILOVAC 28 - 1800 Vdc Traditional Contactors EV500 "BUBBA" Contactor 600 Amps, Make & Break Load Switching Product Facts n Very high power sealed contactor n Hydrogen dielectric for power switching high current loads n Excellent for safety disconnect and transfer switch applications n Suited for circuit protection control n Hermetically "Super-sealed" environment uniquely protects contacts and all moving parts; can operate in harsh environments n 600-1000 A continuous carry, dependent on temperature and conductors used n 3,300 A interrupt, 1,000 A make, @ 320 Vdc n 12 and 24 volt coil control options. Call TE for custom options n 360 kW power switch capable n 200C hot power terminals capable n Bi-directional power switching n Auxiliary contacts optional n Built-in dual power coil economizer, 8W holding typical n Versatile power, voltage, and current operating range: 28-1800 Vdc* Coil Data Notes: 1. Current Carry: 750 A @ 25C. Derate 2.5 A/C to 600 A @ 85C for still air, no heat sink. Reference National Electric Code for specific conductor size recommendation versus current. For > 600 A carry, call TE and request the "EV500 Current Carry study" for additional data. 2. See EV500 sales drawing for complete specifications, including normal capacitive pre-charge make, plus abnormal make and break ratings. 12 V 24 V Type Driver 2 Coil Electronic Volts, Nominal* 12 Vdc 24 Vdc Pickup (Close), Max. 9.9 Vdc 19.7 Vdc Hold, Min. 9 Vdc 18 Vdc Dropout (Open), Min. 2 Vdc 4 Vdc Current (@ VsNom / 25C) Inrush 3.3 A 1.7 A Holding, Standby 0.74 A 0.37 A Inrush Time, Max. 300 ms 300 ms Electrical Life Cycles vs Power Switching *Failure mode: Dielectric withstand voltage test @ 2000 Vdc, power terminal to terminal, leakage exceeds 1.0 A. 7 Ordering Information Sample Part Number EV500 4 A Series: Auxiliary Contacts: 4 = Without 5 = With Coil Voltage: A = 12 Vdc B = 24 Vdc Refer to EV500 Sales Drawing for complete specifications. PAGE 61 KILOVAC 28 - 1800 Vdc Traditional Contactors For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Product Specifications Contact Arrangement with Auxiliary Contacts -- Form X -- SPST-NO Form A -- SPST-NO Rated Resistive Load @ 270 Vdc, 85C (Continuous/10 sec) -- 600 A/1,600 A Continuous Current Carry, Max., 25C 1 -- 750 A Overload Current @ 320 Vdc, Max. -- Make (Closed Into) -- 1,000 A Break (Open) -- 3,300 A Contact Resistance, Max. -- 0.0002 ohm Dielectric at Sea Level (Leakage < 1mA) -- Open Power Terminal to Terminal -- 2,000 Vrms Closed Power Terminals to All Other Points -- 2,000 Vrms Shock, 11ms, 1/2 Sine (Peak), Operating -- 30 g Vibration, Sinusoidal (80-2000 Hz, Peak) -- EV500-5 -- 5 g EV500-4 -- 10 g Operating Ambient Temperature Range -- -40C to +85C Load Life (Mechanical/ Electrical) 2 -- See next page Operate Time @ 25C -- Close (Includes Bounce), Typ. -- 40 ms Bounce (After Close Only), Max. -- 5 ms Release Time (Includes Arcing), Max. at 2500 A -- 20 ms Insulation Resistance @ 500 Vdc, Min. -- 100 mohm Weight, Nominal -- 3.38 lb (1.53 kg) KILOVAC 28 - 1800 Vdc Traditional Contactors EV500 "BUBBA" Contactor 600 Amps, Make & Break Load Switching (Continued) Current vs Time Life Ratings and Qualification Test Plan Normal Operations Abnormal Operations Test # 1 2 3 Current -250 A Reference Graph and Test Circuit Diagram (Sht. 8) Voltage 320 V Load Type Capacitive Capacitive Resistive % Pre Charge 90% 70% NA Switch Mode Make Only Make Only Make/Break Sequence 1 10K cycles 10 cycles 2 2 10K 10 2 3 10K 10 2 4 10K 10 2 5 10K 10 2 Etc. Continue Cycling to Relay Failure 4 3300 A 320 V Resistive N/A Break Only 2 -- -- 2 -- The testing objective is to verify proper relay function for a given number of consecutive and cumulative cycles under both normal and abnormal conditions in a variety of load switching applications. The life rating of 40K cycles minimum was calculated with 95% Weibull reliability. Electrical Data (Over Temperature Range -- Max. Terminal Temp. = 200C) For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Make/Break Life for Capacitive & Resistive Loads at 320 Vdc 1,2 -- @ 90% Capacitive Pre-Charge -- 50,000 cycles @ 70% Capacitive Pre-Charge -- 50 cycles @ -250 A (2 Consecutive, Reverse Polarity) 1 -- 10 cycles @ 3300 A (Break only, 2 Consecutive) 1 -- 4 cycles Mechanical Life -- 100,000 cycles AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Notes: 1 Resistive load includes inductance L = 25 H. 2 Testing is limited at this time. Consult TE for official ratings. KILOVAC 28 - 1800 Vdc Traditional Contactors PD350X - 500 Amps "BUBBA" Contactor, Make & Break Load Switching Product Facts n 500 A carry, 1300 A make overload, 3000 A break overload, @ 320 Vdc n Hydrogen dielectric for power switching high current loads n Auxiliary contacts n Coil power economizing -- 8 W holding n Versatile power, voltage, and current operating range n Excellent for safety disconnect and transfer switch applications n Suited for circuit protection and control n Bi-directional power switching n Hermetically-sealed contacts; can operate in harsh environments n Fast operate and release time n Low power consumption Product Specifications Contact Arrangement -- Form X -- SPST-NO Auxiliary Contact (28 Vdc, 0.1 A) -- SPST-NO Rated Resistive Load @ 320 Vdc -- 300 Amps @85C Continuous Current Carry, Max. @ 50C -- 500 A Overload Current @ 320 Vdc -- Make -- 1,300 A Break -- 3,300 A Load Life, @ 320 Vdc, Min. -- See chart at right Contact Resistance, Max. -- End of Life -- 0.0002 ohm Dielectric at Sea Level -- Power Terminals to Coil and All Other Points -- 1,800 Vrms Shock, 11ms, 1/2 Sine (Peak) -- 30 g Vibration, Sinusoidal (55-2000 Hz, Peak) -- 5 g Operating Ambient Temperature Range -- -40C to +85C Operate Time, Including Bounce, Max., 25C -- 40 ms Release Time, Max. -- 20 ms Bounce Time, Max. -- 5 ms Insulation Resistance @ 500 Vdc, Min. -- Initial -- 100 mohm End of Life -- 50 mohm Weight, Nominal -- 3.4 lb (1.52 kg) Electrical Life Cycles vs Power Switching *Failure Mode: Dielectric withstand voltage test @ 2000 Vdc, power terminal to terminal, leakage exceeds 1.0 mA. Current carry: 500 A @ 25C. Derate 2.5 A/C to 350 A @ 85C for still air, no heat sink, AWG# 00 conductor. For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Contact Rating Notes: 1. Maximum continuous current carry = 500A @ 25C = TA, derate 5A/C for higher temp. 2. Maximum interrupt power (break only) = 1 MW @ 200mH inductance. Volts, Nominal 12 V 24 V Pickup, Max. @ 65C 9.9 Vdc 19.7 Vdc Hold, Max. @ 65C 8.5 Vdc 17 Vdc Dropout, Min. @ -35C 1.2 Vdc 2.4 Vdc Coil Power** 25C During Pickup (300 ms) 43 W 43 W While Holding 8W 8W Energy, Magnetic, Max.***.26 J.26 J **Two coils are employed for power economizing subsequent to pickup. During pickup both coils operate in parallel drawing 43 Watts momentarily. After pickup, the electronic economizing system leaves only the holding coil on, drawing 8 Watts @ 25C. Economizing system includes transient voltage suppression. ***Coil energy absorbed internally -4x nominal voltage. Ordering Information Sample Part Number PD350 X B 5 7 Series: Contact Form: X = SPST-NO, Double Make Coil Voltage: A = 12 Vdc, Stud Terminals B = 24 Vdc, Stud Terminals Power Terminals: 5 = Stud Terminals Mounting: 7 = Panel Mount, Captive Bolts PAGE 63 KILOVAC 28 - 1800 Vdc Traditional Contactors Coil Data 7 KILOVAC High Voltage Relays and Contactors AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS KILOVAC High Voltage Relays High Voltage Relays Quick Reference Guide Contact Voltage Vdc 270 Vdc Aerospace 28 Vdc to 1800 Vdc 2.0 kV 3.0 kV 3.5 kV 5.0 kV 7.0 kV 7.5 kV 8.0 kV Isolation Voltage Vdc 2000 2000 2000 2000 2000 2000 2000 1800 1800 1800 1800 1800 2000 2000 3000 3500 3500 3500 5000 5000 5000 5000 5000 5000 5000 7000 7500 7500 8000 8000 8000 8000 8000 8000 8000 8000 Carry Current (Amps DC) 5 5 5 10 10 10 15 5 5 10 10 10 6 15 2 8 15 25 8 30 30 30 25 25 35 6 10 10 6 8 10 12 12 15 25 50 Power Switching Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Carry Only Yes Carry Only Make Only Yes Carry Only Carry Only Yes Yes Yes Yes Yes Yes Carry Only Make Only Make Only Carry Only Make Only Yes Yes Yes Yes No Yes RF Contact Form Ratings No SPST-NO No SPST-NC No SPDT No SPST-NO No SPST-NC No SPDT No SPST-Latch No SPST-NO No SPST-NC No SPST-NO No SPST-NC No SPST-Latch Yes SPST-NO Yes SPDT No SPST-NO No SPDT Yes SPDT Yes SPDT No SPST-NO Yes SPST-NO Yes SPST-NC Yes SPDT Yes SPST-Latch Yes SPDT-Latch Yes SPST-Latch Yes SPST-NO No DPDT No DPDT No SPST-NC No SPDT Yes DPDT Yes SPST-NO Yes SPST-NC No SPDT No SPDT Yes SPST-Latch Part Number Series AP5A AP5B AP5C AP10A AP10B AP10P AP44P PD5A PD5B PD10A PD10B PD10P S06CBA K45C S02DNA HC-5 HC-3* HC-1 S06FNA218 K41A K41B K41C K41P K41R K40P S06HBA KM-13 KM-17 S06JNB HC-6 H-18 K47A K47B HC-4 HC-2 K44P *Consult factory for load switching level. 7 KILOVAC High Voltage Relays For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. PAGE 65 KILOVAC High Voltage Relays KILOVAC High Voltage Relays Quick Reference Guide (Continued) Contact Voltage Vdc 10 kV 12 kV 15 kV 20 kV 25 kV 30 kV 35 kV 50 kV 70 kV Isolation Voltage Vdc 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 12000 12000 15000 15000 15000 15000 15000 15000 15000 15000 15000 15000 15000 20000 25000 25000 25000 25000 25000 25000 25000 25000 25000 25000 30000 30000 35000 35000 35000 35000 50000 50000 70000 70000 70000 Carry Current (Amps DC) 5 5 5-30 5-30 5-30 25 25 25 24 24 30 30 5 12 12 15 15 15 30 30 30 50 50 30 15 18 18 18 30 30 45 55 65 110 30 30 10 10 10 10 10 30 10 10 10 *Consult factory for load switching level. For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Power Switching Yes Yes Special Special Special Special Special Special Special Special Yes Yes Yes Make Only Make Only Yes Yes Yes Yes Carry Only Yes Carry Only Carry Only Special Make Only Special Special Special Special Make Only Special Carry Only Special Carry Only Special Special Make Only Make Only Make Only Make Only Make Only Special Make Only Make Only Make Only RF Contact Form Ratings No SPST-NO No SPST-NC No SPST-NO No SPST-NC No SPDT Yes SPST-NO Yes SPST-NC Yes SPDT Yes SPDT-Latch Yes SPST-Latch Yes DPDT Yes DPDT No SPST-NO No SPDT No SPDT Yes SPDT No SPDT No SPDT No SPDT Yes 4PDT No SPDT Yes SPDT Yes SPDT Yes DPDT No SPST-NC No SPST-NO No SPST-NC No SPDT Yes SPDT No SPST-NO No SPST-NC Yes SPST-NC No SPST-NO Yes SPST-NO Yes SPST-NC Yes SPST-NO No SPDT No SPST-NO No SPST-NC No SPDT No SPDT No SPDT No SPST-NO No SPST-NC No SPDT Part Number Series S05LTA S05LTB K81A K81B K81C K43A K43B K43C K43R K43P H-14 H-16 S05MTA KC-15 KC-16 H-8 KC-14 KC-18 KC-12 H-26 KC-8 KC-2 KC-11 H-19 KC-38 K62A K62B K62C H-17 KC-28 KC-32 KC-30 KC-22 KC-20 H-23 H-24 K60C K61A K61B K61C K64C H-25 K70A K70B K70C KILOVAC 270+ Vdc High Voltage Relays AP5/AP10 Relays Product Facts n AP5 make and break 5 A; AP10 make and break 10 A @ 270 Vdc n 20 A overload rating n Latching actuator available for low power consumption n Ideal for applications from 28 to 1000 Vdc n Small size and weight n Wide variety of mounting styles (see pages 54 and 55) n No heat sinks required n 2000 V isolation across open contacts n Vacuum-sealed contacts; can operate in harsh environments n Qualified to SAE ARD 50031 n Space-rated version built in accordance with customers SCD Notes: *The load terminals should always be connected as follows: Common Contact +; Other Contact -. **10 amps for PC board connection. AP5A, AP5B, & AP5C Relays -- 5 Amps Product Specifications Contact Arrangement -- AP5A -- SPST-NO AP5B -- SPST-NC AP5C -- SPDT Contact Form -- AP5A -- A AP5B -- B AP5C -- C Rated Resistive Load @ 270 Vdc -- 5 A* Continuous Current Carry, Max. -- AP5A, AP5B, AP5C -- 25 A** Operate Time, Excluding Bounce, Max. -- AP5A, AP5B, AP5C -- 7 ms Release Time, Max. -- AP5A, AP5B, AP5C -- 10 ms Bounce Time, Max. -- AP5A, AP5B, AP5C -- 3 ms Insulation Resistance @ 500 Vdc, Min. -- Initial -- 100 mohm End of Life -- 50 mohm Weight, Nominal -- 28 gram (1 oz.) AP10A, AP10B, AP10P & AP11A Relays -- 10 Amps Product Specifications Contact Arrangement -- AP10A -- SPST-NO AP10B -- SPST-NC AP10P -- SPST Latching Contact Form -- AP10A -- A AP10B -- B AP10P -- P Rated Resistive Load @ 270 Vdc -- 10 A* Continuous Current Carry, Max. -- AP10A, AP10B -- 25 A** AP10P -- 30 A** Overload @ 270 Vdc -- 20 A Contact Resistance, Max. -- 10 mohm Dielectric at Sea Level -- Coil to Case -- 500 Vrms All Other Points -- 2,000 Vrms Shock, 11ms, 1/2 Sine (Peak) -- 50 g Volts, Nominal 12 28 28 2 120 10 Vdc 20 Vdc 16 Vdc 85 Vdc Pickup, Max. 1 Dropout, Min. .3-6 Vdc .7-12 Vdc N/A 5-55 Vdc Coil Resistance (10%) 53 290 80 4700 Coil resistance rated at 25C Notes: 1. Value for AP5C is 24 for 28 Vdc coil & 100 for 120 Vdc coil 2. Latching Vibration, Sinusoidal (55-2000 Hz, Peak) -- 10 g Operating Ambient Temperature Range -- -55C to +85C Load Life @ 270 Vdc, Min. -- AP10A -- 10,000 cycles AP10B, AP10P -- 7,000 cycles Operate Time, Excluding Bounce, Max. -- AP10A, AP10B -- 7 ms AP10P -- 4 ms Release Time, Max. -- AP10A, AP10B -- 10 ms AP10P -- N/A Bounce Time, Max. -- AP10A, AP10B -- 3 ms AP10P -- 2 ms Insulation Resistance @ 500 Vdc, Min. -- Initial -- 100 mohm End of Life -- 50 mohm Weight, Nominal -- 28 gram (1 oz.) Ordering Information AP5 C 3 4 5 Sample Part Number Series: Contact Form: A = SPST-NO P = SPST Latching B = SPST-NC 7 C = SPDT Coil Voltage: 2 = 12Vdc, Bus Wire/PC Board 3 = 28 Vdc, Bus Wire/PC Board 5 = 120 Vdc, Bus Wire/PC Board 7 = 12 Vdc, Turret Terminals 8 = 28 Vdc, Turret Terminals 9 = 120 Vdc, Turret Terminals A = 12 Vdc, Stud Terminals, Panel Mount B = 28 Vdc, Stud Terminals, Panel Mount C = 120 Vdc, Stud Terminals, Panel Mount Power Terminals: 3 = Solder Connection/PC Board 5 = Stud Terminals, Panel Mount Mounting: 2 = Flanged Mount 5 = PCB Mount KILOVAC 270+ Vdc High Voltage Relays Coil Data For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Overload @ 270 Vdc -- AP5A, AP5B -- 20 A AP5C-- 10 A Contact Resistance, Max. -- 10 mohm Dielectric at Sea Level -- Coil to Case -- 500 Vrms All Other Points -- 2,000 Vrms Shock, 11ms, 1/2 Sine (Peak) -- AP5A, AP5B, AP5C-- 50 g Vibration, Sinusoidal (55-2000 Hz, Peak) -- 10 g Operating Ambient Temperature Range -- -55C to +85C Load Life @ 270 Vdc, Min. -- AP5A, AP5B -- 50,000 cycles AP5C -- 10,000 cycles 4 = Flying Leads 4 = Through Chassis Mount 7 = Panel Mount PAGE 67 KILOVAC 270+ Vdc High Voltage Relays AP5/AP10 Relays (Continued) Through chassis style mounting with solder type power terminals and turret coil terminals (Available in forms A, B, & C) AP5A834 Shown as Part Number Sample Through chassis style mounting with solder type power terminals and bus wire coil leads (Available in forms A, B, C, P) AP10A334 Shown as Part Number Sample Flanged style mounting with solder type power terminals and turret coil terminals (Available in forms A, B, & C) AP5C832 Shown as Part Number Sample Flanged style mounting with solder type power terminals and bus wire coil leads (Available in forms A, B, C, P) AP5C332 Shown as Part Number Sample For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS KILOVAC 270+ Vdc High Voltage Relays AP5/AP10 Relays (Continued) PC board style mounting with PC board terminals (Available in forms A, B, & C) AP10A335 Shown as Part Number Sample Panel style mounting with flying power leads and stud terminals (Available in forms A & B) AP10AB47 Shown as Part Number Sample 7 KILOVAC 270+ Vdc High Voltage Relays Panel style mounting with stud terminals (Available in forms A & B) AP10AB57 Shown as Part Number Sample For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. PAGE 69 KILOVAC 270+ Vdc High Voltage Relays AP44P -- 15 Amps Product Facts n 15 A make and break @ 270 Vdc n 45 A carry n 60 A overload rating n Ideal for high voltage applications from 28 to 270 Vdc n Latching actuator for low power consumption n 2000 V isolation across open contacts n Small size and weight n Space-rated version built in accordance with customers SCD n Meets many requirements of MIL-PRF-32085 Product Specifications Contact Arrangement -- SPST Latching Contact Form -- P Rated Resistive Load @ 270 Vdc -- 15 A* Continuous Current Carry, Max. -- 45 A Overload @ 270 Vdc -- 60 A Contact Resistance, Max. -- 10 mohm Dielectric at Sea Level -- Coil to Case -- 500 Vrms All Other Points -- 2,000 Vrms Shock, 11ms, 1/2 Sine (Peak) -- 50 g Vibration, Sinusoidal (55-2000 Hz, Peak) -- 15 g** Operating Ambient Temperature Range -- -55C to +85C Load Life @ 270 Vdc, Min. -- 5,000 cycles Operate Time, Excluding Bounce, Max. -- 2 ms Release Time, Max. -- N/A Bounce Time, Max. -- 3 ms Coil Data AP44P 28 Latching Latch, Max. 22 Vdc Reset, Max. 22 Vdc Coil Resistance (10%) 80 Coil resistance rated at 25C Ordering Information Sample Part Number Series: Contact Form: P = SPST Latching Coil Voltage: 3 = 28 Vdc, Bus Wire Power Terminals: 3 = Solder Connection For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Mounting: 4 = Standard AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS PD5 A 2 3 5 Latch/Reset Time, Including Bounce, Max. -- 5 ms Insulation Resistance @ 500 Vdc, Min. -- Initial -- 100 mohm End of Life -- 50 mohm Weight, Nominal -- 43 gram (1.5 oz.) Notes: *The load terminals should always be connected as follows: Common Contact +; Other Contact -. KILOVAC 280 - 1800 Vdc High Voltage Relays PD5 Make & Break Load Switching Product Facts n Vacuum dielectric for power switching n Excellent for control applications n PCB and panel mountings n Rugged design for the most demanding applications, including seismic shock n Small size and weight n Low power consumption n No heat sinks required n Vacuum-sealed; can operate in explosive and harsh environments n 2000 V isolation across open contacts Contact Ratings* Product Specifications Note: **Contact TE for availability of other contact forms For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. *Based on extrapolated data. Since each application is unique, user is encouraged to verify rating in actual application. The load terminals should always be connected as follows: Common Contact (A2) positive; Other Contact negative. Coil Data Nominal Volts DC Max. Coil Voltage Pickup, Max. @ 85C Hold, Min. @ 85C Dropout, Min. @ -40C Coil Resistance (10%) 12 Vdc 14 Vdc 8 Vdc 3.3 Vdc .5 Vdc 70 24 Vdc 28 Vdc 16 Vdc 10 Vdc 1 Vdc 290 125 Vdc 130 Vdc 80 Vdc 33 Vdc 5 Vdc 4700 Ratings listed are for 25C, sea level conditions Ordering Information PD5 A 2 3 5 Sample Part Number Series: Contact Form: A = SPST-NO B = SPST-NC C = SPDT (PCB Only) Coil Voltage: 2 = 12 Vdc, PCB Version 3 = 24 Vdc, PCB Version 5 = 125 Vdc, PCB Version A = 12 Vdc, Panel Mount Version B = 24 Vdc, Panel Mount Version C = 125 Vdc, Panel Mount Version Power Terminals: 3 = PCB Solder Connection 5 = Stud Terminal, Panel Mount Mounting: 5 = PCB Mount 7 KILOVAC 280 - 1800 Vdc High Voltage Relays Contact Arrangement -- PD5A -- SPST-NO PD5B -- SPST-NC Contact Form -- PD5A -- A** PD5B -- B** Rated Resistive Load @ 320 Vdc --5A Continuous Current Carry, Max. @ 85C -- 15 A Overload @ 320 Vdc, (Make/ Break) -- 20 A Life, (Mechanical/Rated Load) -- 500k cycles/50k cycles Contact Resistance, Max., End of Life -- 0.010 ohm Dielectric at Sea Level -- Power Terminals to Coil and All Other Points -- 1,800 Vrms Shock, 11ms, 1/2 Sine (Peak) -- 25 g Vibration, Sinusoidal (55-2000 Hz, Peak) -- 5 g Operating Ambient Temperature Range -- -40C to +85C Operate Time, Max., Including Bounce @ 25C -- 10 ms Release Time, Max., Including Bounce @ 25C -- 10 ms Insulation Resistance @ 500 Vdc, Min. -- Initial/End of Life -- 100 mohm/50 mohm Weight, Nominal -- 57 g (.125 lb) 7 = Panel Mount PAGE 71 KILOVAC 280 - 1800 Vdc High Voltage Relays PD10 Make & Break Load Switching Product Facts n Excellent for control applications n PCB and panel mountings n Rugged design for the most demanding applications, including seismic shock n Small size and weight n Low power consumption n No heat sinks required n Vacuum-sealed; can operate in explosive and harsh environments n 2000 V isolation across open contacts n Vacuum dielectric for power switching For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Panel mount version shown above is applicable to both PD5 and PD10. For PD10, the two power terminals are .064" (1.63) diameter. Refer to PD5 for PCB mount dimensions. Product Specifications Contact Arrangement -- PD10A -- SPST-NO PD10B -- SPST-NC PD10P*** -- SPST-Latching Contact Form -- PD10A -- A** PD10B -- B** PD10P*** -- P** Rated Resistive Load @ 320 Vdc -- 10 A Continuous Current Carry, Max. @ 85C -- PD10A and PD10B -- 25 A PD10P*** -- 30 A Overload @ 320 Vdc, (Make/ Break) -- 20 A Contact Ratings* Life, (Mechanical/Rated Load) -- PD10A and PD10B -- 500k cycles/10k cycles PD10P*** -- 7,000 cycles Contact Resistance, Max., End of Life -- PD10A and PD10B -- 0.010 ohm PD10P*** -- 0.030 ohm Dielectric at Sea Level -- Power Terminals to Coil and All Other Points -- PD10A and PD10B -- 1,800 Vrms PD10P*** -- 2,000 Vrms Shock, 11ms, 1/2 Sine (Peak) -- 25 g Vibration, Sinusoidal (55-2000 Hz, Peak) -- 5 g Operating Ambient Temperature Range -- PD10A and PD10B -- -40C to +85C PD10P*** -- -35C to +65C Operate Time, Max., Including Bounce @ 25C -- PD10A and PD10B -- 10 ms PD10P*** -- 6 ms Release Time, Max., Including Bounce @ 25C -- PD10A and PD10B -- 10 ms PD10P*** -- 6 ms Insulation Resistance @ 500 Vdc, Min. -- Initial/End of Life -- 100 mohm/50 mohm Weight, Nominal -- 71 g (.156 lb) Notes: **Contact TE for availability of other contact forms ***Not available in package shown, package is the same as the K41P. Ordering Information PD10 A A 5 7 Sample Part Number Series: *Based on extrapolated data. Since each application is unique, user is encouraged to verify rating in actual application. The load terminals should always be connected as follows: Common Contact (A2) positive; Other Contact negative. Coil Data Nominal Volts DC Max. Coil Voltage Pickup, Max. @ 85C Hold, Min. @ 85C Dropout, Min. @ -40C Coil Resistance (10%) 12 Vdc 14 Vdc 8 Vdc 3.3 Vdc .5 Vdc 70 24 Vdc 28 Vdc 16 Vdc 10 Vdc 1 Vdc 290 125 Vdc 130 Vdc 80 Vdc 33 Vdc 5 Vdc 4700 Ratings listed are for 25C, sea level conditions AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Contact Form: A = SPST-NO B = SPST-NC P = SPST-Latching Coil Voltage: 2 = 12 Vdc, PCB Version 3 = 24 Vdc, PCB Version 5 = 125 Vdc, PCB Version A = 12 Vdc, Panel Mount Version B = 24 Vdc, Panel Mount Version C = 125 Vdc, Panel Mount Version Power Terminals: 3 = PCB Solder Connection 5 = Stud Terminal, Panel Mount Mounting: 5 = PCB Mount 7 = Panel Mount KILOVAC High Voltage Relays K45 Series Make & Break Load Switching -- 1.5 - 2 kV Relays K45C Product Facts n Small, low profile 2 kV relay n Vacuum dielectric for power switching low current loads n Single pole, double throw contacts n Widely used in H.F. communication equipment n Meets requirements of MIL-R-83725 n Low power consumption Product Specifications Contact Arrangement -- SPDT Contact Form -- C Test Voltage, DC or 60 Hz (Peak) -- 4 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 2 kV 2.5 MHz -- 1.8 kV 16 MHz -- 1.4 kV 32 MHz -- 1.1 kV Vibration -- Peak -- 10 g (10 to 2000 Hz) Operating Ambient Temperature Range -- -55C to +125C Mechanical Life 2 million cycles Weight, Nominal -- 21.26 g (0.75 oz.) Ordering Information Coil Data 12 V 8 Vdc 8.5 Vdc .5-5 Vdc 230 Ratings listed are for 25C, sea level conditions. 26.5 V 16 Vdc 17 Vdc 1-10 Vdc 920 Sample Part Number K45 C 3 3 4 Series: Contact Form: C = SPDT Coil Voltage: 2 = 12 Vdc, Bus Wire 3 = 26.5 Vdc, Bus Wire High Voltage Connections: 3 = Solder Connection For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Mounting: 2 = Flanged 4 = Standard See page 7-87 for mounting methods. PAGE 73 7 KILOVAC High Voltage Relays Volts, Nominal DC Pickup, Max. Hold, Max. @ 65C Dropout Coil Resistance (10%) Continuous Carry Current, Max. -- DC or 60 Hz -- 20 A 2.5 MHz -- 16 A 16 MHz -- 10 A 32 MHz -- 6 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Capacitance -- Between Open Contacts -- 1.6 pF Open Contacts to Ground -- 2 pF Contact Resistance, Max. -- 0.05 ohm Operate Time, Max. -- 10 ms Release Time, Max. -- 10 ms Shock, 11ms, 1/2 Sine (Peak) -- 30 g KILOVAC High Voltage Relays HC Series -- 3.5 kV Relays HC-1 No Load Switching HC-3 Make & Break Load Switching Product Facts for HC-1 n Widely used for RF applications n Vacuum dielectric for low leakage current applications n Copper contacts for high current capability n Not designed for power switching n Meets requirements of MIL-R-83725 n QPL version available, M83725/5-001 Product Facts for HC-3 n Tungsten contacts for long life when power switching n For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Vacuum dielectric for power switching low current loads HC-5 Make Only Load Switching Product Facts for HC-5 n Gas-filled for "make only" power switching n SF-6 gas-filled for capacitive discharge applications n Tungsten contacts for long life when power switching Product Specifications for HC-1, HC-3 and HC-5 Contact Arrangement -- SPDT Contact Form -- C Test Voltage, DC or 60 Hz (Peak) -- 5 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 3.5 kV 2.5 MHz -- 2.5 kV 16 MHz -- 2 kV 32 MHz -- 1.5 kV Continuous Carry Current, Max. -- DC or 60 Hz -- H C-1 -- 25 A HC-3 -- 18 A HC-5 -- 8 A 2.5 MHz -- HC-1 -- 14 A 16 MHz -- HC-1 -- 9 A 32 MHz -- HC-1 -- 7 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Capacitance -- Between Open Contacts -- HC-1 --2 pF Open Contacts to Ground -- HC-1 --2.5 pF Contact Resistance, Max. -- HC-1 -- 0.01 ohm HC-3 -- 0.02 ohm HC-5 -- 0.50 ohm* Operate Time, Max. -- 6 ms Release Time, Max. -- 6 ms Shock, 11ms, 1/2 Sine (Peak) -- 50 g Vibration -- Peak -- 10 g (55 to 2000 Hz) Operating Ambient Temperature Range -- -55C to +125C Mechanical Life -- HC-1, HC-3 -- 2 million cycles HC-5 -- 1 million cycles Weight, Nominal -- 28.35 g (1.0 oz.) Note: *Contact resistance for gas-filled relays is measured at 28 Vdc, 1 Amp AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Coil Data Pickup, Max. Dropout Coil Resistance (10%) 8 Vdc .5-5 Vdc 80 16 Vdc 1-10 Vdc 335 80 Vdc 5-50 Vdc 6000 Ratings listed are for 25C, sea level conditions Ordering Information Sample Part Number Series: Model: 1 3 5 Coil Voltage: Blank = 26.5 Vdc /12Vdc = 12 Vdc /115Vdc = 115 Vdc HC- 1 /12Vdc KILOVAC High Voltage Relays K41 Series Make & Break Load Switching -- 5.0 kV Relays K41A, K41B Product Facts n n n n n n High current carry rating Vacuum dielectric for power switching low current loads Glazed ceramics for low current leakage Compact, space-saving design Meets requirements of MIL-R-83725 QPL versions available, M83725/21 & M83725/22 K41C Product Facts n n n n n n Single pole, double throw version Vacuum dielectric for power switching low current loads RF ratings to 32 MHz Long life: 2 million cycles Meets requirements of MIL-R-83725 QPL version available, M83725/23 Product Specifications for K41A, K41B and K41C For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Contact Capacitance -- Between Open Contacts -- 1.2 pF Open Contacts to Ground -- 1.2 pF Contact Resistance, Max. -- 0.02 ohm Operate Time, Max. -- 10 ms Release Time, Max. -- 10 ms Shock, 11ms, 1/2 Sine (Peak) -- 50 g Vibration -- Peak -- 10 g (55 to 2000 Hz) Operating Ambient Temperature Range -- -55C to +125C Mechanical Life -- 2 million cycles Weight, Nominal -- 28.35 g (1.0 oz.) *See page 7-87 for turret terminal dimensions and mounting methods. Coil Data Nominal Volts DC Pickup, Max. Dropout Coil Resistance (10%) 12 Vdc 8 Vdc .5-5 Vdc 70 26.5 Vdc 16 Vdc 1-10 Vdc 290 115 Vdc 80 Vdc 5-50 Vdc 4700 Ratings listed are for 25C, sea level conditions Ordering Information K41 A 3 3 4 Sample Part Number Series: Contact Form: A = SPST-NO B = SPST-NC C = SPDT Coil Voltage: 2 = 12 Vdc, Bus Wire 3 = 26.5 Vdc, Bus Wire 5 = 115 Vdc, Bus Wire 7 = 12 Vdc, Turret Terminal* 8 = 26.5 Vdc, Turret Terminal* 9 = 115 Vdc, Turret Terminal* High Voltage Connections: 3 = Solder Connection Mounting: 2 = Flanged 4 = Standard PAGE 75 7 KILOVAC High Voltage Relays Contact Arrangement -- K41A -- SPST-NO K41B -- SPST-NC K41C -- SPDT Contact Form -- K41A -- A K41B -- B K41C -- C Test Voltage, DC or 60 Hz (Peak) -- 6 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 5 kV 2.5 MHz -- 4.5 kV 16 MHz -- 3.5 kV 32 MHz -- 2.8 kV Continuous Carry Current, Max. -- DC or 60 Hz -- 30 A 2.5 MHz -- 24 A 16 MHz -- 16 A 32 MHz -- 12 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A KILOVAC High Voltage Relays K41 Series Make & Break Load Switching -- 5.0 kV Relays K41P Product Facts n n n n n n Fast, 6 millisecond operate time Vacuum dielectric for power switching low current loads Latching actuator for low power consumption Ideal for frequency agile communication systems Meets requirements of MIL-R-83725 QPL version available, M83725/24 K41R Product Facts n n n n Latching actuator for low power consumption Vacuum dielectric for power switching low current loads Meets requirements of MIL-R-83725 Latching version of K41C Product Specifications for K41P and K41R Contact Arrangement -- K41P -- SPST-Latching K41R -- SPDT-Latching Contact Form -- K41P -- P K41R -- R Test Voltage, DC or 60 Hz (Peak) -- 6 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 5 kV 2.5 MHz -- K41P -- 4.5 kV K41R -- 4.0 kV 16 MHz -- K41P -- 3.5 kV K41R -- 3.2 kV 32 MHz -- K41P -- 2.8 kV K41R -- 2.5 kV Continuous Carry Current, Max. -- DC or 60 Hz -- 30 A 2.5 MHz -- K41P -- 20 A K41R -- 16 A 16 MHz -- K41P -- 13 A K41R -- 10 A 32 MHz -- K41P -- 10 A K41R -- 6 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Capacitance -- Between Open Contacts -- K41P -- 1.2 pF K41R -- 1.6 pF Open Contacts to Ground -- K41P -- 1.2 pF K41R -- 1.6 pF Contact Resistance, Max. -- 0.02 ohm Operate Time, Max. -- 6 ms Release Time, Max. -- N/A Shock, 11ms, 1/2 Sine (Peak) -- K41P -- 50 g K41R -- 30 g Vibration -- Peak -- 10 g (55 to 2000 Hz) Operating Ambient Temperature Range -- -55C to +125C Insulation Resistance -- Initial -- 10 gigaohms Mechanical Life -- 1 million cycles Weight, Nominal -- 28.35 g (1.0 oz.) For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Coil Data Volts, Nominal 26.5 Vdc Reset & Latch, Max. 16 Vdc Dropout N/A Coil Resistance (10%) 80 Ratings listed are for 25C, sea level conditions. Ordering Information K41 P 3 3 4 Sample Part Number Series: Contact Form: P = SPST-Latching R = SPDT-Latching Coil Voltage: 3 = 26.5 Vdc, Bus Wire High Voltage Connections: 3 = Solder Connection Mounting:* 2 = Flanged 4 = Standard *See page 7-87 for mounting methods. KILOVAC High Voltage Relays K40P Make & Break Load Switching -- 5.0 kV Relays Product Facts for K40P n n n n n n Vacuum dielectric for power switching low current loads Fast, 1 millisecond operate time Long life: 10 million cycles 35 Amps continuous current rating at DC; 8 Amps at 32 MHz Ideal for high power antenna couplers Meets requirements of MIL-R-83725 Product Facts for K40P364 n n n n Double sided terminals for ease of connection to bus bar Vacuum dielectric for power switching low current loads Fast switching, high current capabilities Small and lightweight Product Specifications Contact Capacitance -- Between Open Contacts -- 1.2 pF Open Contacts to Ground -- 1.2 pF Contact Resistance, Max. -- 0.02 ohm Operate Time, Max. -- 1 ms Release Time, Max. -- N/A Shock, 11ms, 1/2 Sine (Peak) -- 50 g Vibration -- Peak -- 30 g (55 to 2000 Hz) Operating Ambient Temperature Range -- -55C to +125C Mechanical Life --10 million cycles Weight, Nominal -- 28.35 g (1.0 oz.) Coil Data Volts, Nominal 26.5 Vdc Reset & Latch, Max. 16 Vdc Dropout N/A Coil Resistance (10%) 80 7 Ratings listed are for 25C, sea level conditions. Ordering Information K40 P 3 3 2 Sample Part Number Series: Contact Form: P = SPST-Latching Coil Voltage: 3 = 26.5 Vdc, Bus Wire High Voltage Connections: 3 = Solder Connection 6 = Double Sided Solder Connection For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Mounting:* 2 = Flanged 4 = Standard *See page 7-87 for mounting methods. PAGE 77 KILOVAC High Voltage Relays Contact Arrangement -- SPST-Latching Contact Form -- P Test Voltage, DC or 60 Hz (Peak) -- 6 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 5 kV 2.5 MHz -- 4.5 kV 16 MHz -- 3.5 kV 32 MHz -- 2.8 kV Continuous Carry Current, Max. -- DC or 60 Hz -- 35 A 2.5 MHz -- 21 A 16 MHz -- 14 A 32 MHz -- 8 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A KILOVAC High Voltage Relays KM-17 Series Make Only Load Switching -- 7.5 kV Relays Product Facts n Double pole, double throw contacts n SF-6 gas-filled for ideal discharge waveform n High voltage flying leads n Tabs for easy mount n Widely used in defibrillator applications Product Specifications for KM-17 Contact Arrangement -- DPDT Contact Form -- 2C Test Voltage, DC or 60 Hz (Peak) -- 14 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 7.5 kV Continuous Carry Current, Max. -- DC or 60 Hz -- 1 0 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Capacitance -- Between Open Contacts -- N/A Open Contacts to Ground -- N/A Contact Resistance, Max. -- 0.5 ohm* Operate Time, Max. -- 20 ms Release Time, Max. -- 20 ms Shock, 11ms, 1/2 Sine (Peak) -- 10 g Vibration -- Peak -- 10 g (55 to 500 Hz) Operating Ambient Temperature Range -- -20C to +65C Insulation Resistance -- Initial -- 10 gigaohms Mechanical Life -- 10l0,000 cycle Weight, Nominal -- KM-17 -- 311.8 g (11 oz.) Ordering Information Sample Part Number Series: Model: 17 Coil Voltage: Blank = 12 Vdc /26.5Vdc = 26.5 Vdc Coil Data Nominal Volts DC Pickup, Max. Dropout Coil Resistance (10%) 12 Vdc 8 Vdc .5-5 Vdc 12 26 Vdc 16 Vdc 1-10 Vdc 48 Ratings listed are for 25C, sea level conditions Coils are not for continuous duty. For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS KM- 17 /26Vdc KILOVAC High Voltage Relays K47 Series Make & Break Load Switching -- 8 kV Relays K47A Product Facts for K47A n n n n n Widely used in antenna coupler applications Short actuator, low profile, 8 kV relay Vacuum dielectric for power switching low current loads Normally open contacts Meets requirements of MIL-R-83725 K47B Product Facts for K47B n n n n n Normally closed version of K47 Vacuum dielectric for power switching low current loads 707 Ohm coil for low power consumption Meets requirements of MIL-R-83725 QPL version available, M83725/18-003 Product Specifications for K47A and K47B For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Contact Resistance, Max. -- 0.03 ohm Operate Time, Max. -- 10 ms Release Time, Max. -- 10 ms Shock, 11ms, 1/2 Sine (Peak) -- 30 g Vibration -- Peak -- 10 g (55 to 1000 Hz) Operating Ambient Temperature Range -- -55C to +125C Mechanical Life -- 2 million cycles Weight, Nominal -- 25.5 g (0.9 oz.) Coil Data Nominal Volts DC Pickup, Max. Dropout Coil Resistance (10%) 12 Vdc 8 Vdc .5-5 Vdc 230 26.5 Vdc 16 Vdc 1-10 Vdc 707 Ratings listed are for 25C, sea level conditions 7 Ordering Information K47 A 3 3 4 Sample Part Number Series: Contact Form: A = SPST-NO B = SPST-NC Coil Voltage: 2 = 12 Vdc, Bus Wire 3 = 26.5 Vdc, Bus Wire High Voltage Connections: 3 = Solder Connection *See page 7-87 for mounting methods. Mounting: 2 = Flanged 4 = Standard PAGE 79 KILOVAC High Voltage Relays Contact Arrangement -- K47A -- SPST-NO K47B -- SPST-NC Contact Form -- K47A -- A K47B -- B Test Voltage, DC or 60 Hz (Peak) -- 9 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 8 kV 2.5 MHz -- 7.5 kV 16 MHz -- 7 kV 32 MHz -- 5 kV Continuous Carry Current, Max. -- DC or 60 Hz -- 12 A 2.5 MHz -- 10 A 16 MHz -- 5 A 32 MHz -- 3 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Capacitance -- Between Open Contacts -- 1.2 pF Open Contacts to Ground -- 1.2 pF KILOVAC High Voltage Relays HC Series -- 8 kV Relays HC-2 No Load Switching HC-4 Make & Break Load Switching Product Facts for HC-2 n Vacuum dielectric and copper contacts for high current carry rating of 25 Amps n Not designed for power switching n Stable, low contact resistance n Product Facts for HC-4 n Tungsten contacts for long life in power switching applications n Vacuum dielectric for arc suppression when making or breaking a load Meets requirements of MIL-R-83725 n Meets requirements of MIL-R-83725 HC-6 Make Only Load Switching Product Facts for HC-6 n Tungsten contacts for switching high in-rush loads n SF-6 gas-filled for capacitive discharge applications n Suitable for ESD testing applications n Tungsten contacts for long life in power switching applications Product Specifications for HC-2, HC-4 and HC-6 Contact Arrangement -- SPDT Contact Form -- C Test Voltage, DC or 60 Hz (Peak) -- 10 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 8 kV Continuous Carry Current, Max. -- DC or 60 Hz -- H C-2 -- 25 A RMS HC-4 -- 15 A RMS HC-6 -- 8 A RMS Coil Hi-Pot (Vrms, 60 Hz) -- 500 A RMS Contact Capacitance -- Between Open Contacts -- N/A Open Contacts to Ground -- N/A Contact Resistance, Max. -- HC-2 -- 0.01 ohm HC-4 -- 0.02 ohm HC-6 -- 0.5 ohm* Operate Time, Max. -- 6 ms Release Time, Max. -- 6 ms Shock, 11ms, 1/2 Sine (Peak) -- 50 g Vibration -- Peak -- 10 g (55 to 2000 Hz) Operating Ambient Temperature Range -- -55C to +125C Mechanical Life -- HC-2 and HC-4 -- 2 million cycles HC-6 -- 1 million cycle Weight, Nominal -- 39.69 g (1.4 oz.) *Contact resistance for gas-filled relays is measured at 28 Vdc, 1 Amp Coil Data Nominal Volts DC Pickup, Max. Dropout Coil Resistance (10%) 12 Vdc 8 Vdc .5-5 Vdc 80 Ordering Information HC- 6 /12Vdc Series: Model: 2 AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS 115 Vdc 80 Vdc 5-50 Vdc 6000 Ratings listed are for 25C, sea level conditions Sample Part Number For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. 26.5 Vdc 16 Vdc 1-10 Vdc 335 4 Coil Voltage: Blank = 26.5 Vdc /12Vdc = 12 Vdc /115Vdc = 115 Vdc 6 KILOVAC High Voltage Relays H-18 Series Make & Break Load Switching -- 8 kV Relays Product Facts n Smallest DPDT high voltage relay n Vacuum dielectric for power switching low current loads n 8 kV rating; carries 2 Amps at 32 MHz n Tungsten contacts for power switching low current loads n Meets requirements of MIL-R-83725 Product Specifications Contact Arrangement -- DPDT Contact Form -- 2C Test Voltage, DC or 60 Hz (Peak) -- 10 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 8 kV 2.5 MHz -- 5 kV 16 MHz -- 3 kV 32 MHz -- 2 kV Shock, 11ms, 1/2 Sine (Peak) -- 30 g Vibration -- Peak -- 10 g (55 to 500 Hz) Operating Ambient Temperature Range -- -55C to +125C Mechanical Life -- 1 million cycles Weight, Nominal -- 70.87 g (2.5 oz.) Ordering Information Coil Data 12 V 8 Vdc .5-5 Vdc 60 26.5 V 16 Vdc 1-10 Vdc 250 115 V 80 Vdc 5-50 Vdc 3500 Sample Part Number H-18 /12Vdc Series: Model: H-18 Coil Voltage: Blank = 26.5 Vdc /12Vdc = 12 Vdc /115Vdc = 115 Vdc For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. PAGE 81 7 KILOVAC High Voltage Relays Volts, Nominal DC Pickup, Max. Dropout Coil Resistance (10%) Continuous Carry Current, Max. -- DC or 60 Hz -- 10 A 2.5 MHz -- 7 A 16 MHz -- 3 A 32 MHz -- 2 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Capacitance -- Between Open Contacts -- 0.8 pF Open Contacts to Ground -- 1.5 pF Contact Resistance, Max. -- 0.02 ohm Operate Time, Max. -- 15 ms Release Time, Max. -- 15 ms KILOVAC High Voltage Relays K44P Make & Break Load Switching -- 9 kV Relays Product Facts n Single pole, single throw contacts with latching actuator n Vacuum dielectric for power switching low current loads n 20 G vibration rating n Carries 50 Amps at DC n Space rated versions available n Meets requirements of MIL-R-83725 Product Specifications Contact Arrangement -- SPST-Latching Contact Form -- P Test Voltage, DC or 60 Hz (Peak) -- 9kVdc Rated Operating Voltage (Peak) -- DC or 60 Hz -- 8 kV 2.5 MHz -- 7 kV 16 MHz -- 6 kV 32 MHz -- 4 kV Continuous Carry Current, Max. -- DC or 60 Hz -- 50 A 2.5 MHz -- 40 A 16 MHz -- 25 A 32 MHz -- 20 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Capacitance -- Between Open Contacts -- 2.5 pF Open Contacts to Ground -- 2.8 pF Contact Resistance, Max. -- 0.01 ohm Operate Time, Max. -- 5 ms Release Time, Max. -- N/A Shock, 11ms, 1/2 Sine (Peak) -- 50 g Vibration -- Peak -- 20 g (55 to 2000 Hz) Operating Ambient Temperature Range -- -55C to +85C Mechanical Life -- 1 million cycles Weight, Nominal -- 59.53 g (2.1 oz.) For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Coil Data Volts, Nominal 26.5 Vdc Latch & Reset, Max. 23 Vdc Dropout N/A Coil Resistance (10%) 155 Ratings listed are for 25C, sea level conditions Ordering Information K44 P 3 3 4 Sample Part Number Series: Contact Form: P = SPST-Latching Coil Voltage: 3 = 26.5 Vdc, Bus Wire High Voltage Connections: 3 = Solder Connection Mounting: 2 = Flanged 4 = Standard *See page 7-87 for mounting methods. KILOVAC High Voltage Relays K81 A/B Series Make & Break Load Switching -- 10 kV Relays Product Facts n 10 kV PC board-mount relay n Vacuum dielectric for power switching low current loads n Flying leads or PCB mount for high voltage connections n Meets requirements of MIL-R-83725 n Completely sealed; suitable for test equipment n Panel mount available for ease of mounting Product Specifications For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Operating Ambient Temperature Range -- -55C to +85C Mechanical Life -- 2 million cycles Weight, Nominal -- 56.7 g (2 oz.) Notes: 1. PC pin versions carry 5 or 20 Amps, see part number at right. Flying lead and panel versions carry 30 Amp. *Power terminal on 20 Amp version is a larger diameter than on the 5 Amp version (.025 = 5 Amp, .064 = 20 Amp) Coil Data Volts, Nominal DC Pickup, Max. Dropout Coil Resistance (10%) 12 V 8 Vdc .5-5 Vdc 70 26.5 V 16 Vdc 1-10 Vdc 290 115 V 80 Vdc 5-50 Vdc 4700 Ratings listed are for 25C, sea level conditions Ordering Information K81 A 3 3 5 Sample Part Number Series: Contact Form: A = SPST-NO B = SPST-NC Coil Voltage: 2 = 12 Vdc, PC Board 3 = 26.5 Vdc, PC Board 5 = 115 Vdc, PC Board A = 12 Vdc, Stud Terminals, Panel Mount B = 26.5 Vdc, Stud Terminals, Panel Mount C = 115 Vdc, Stud Terminals, Panel Mount High Voltage Connections: A* = PCB Solder Connection -- 20 Amp 3 = PCB Solder Connection -- 5 Amp 4 = Flying Leads 5 = Stud Terminals Mounting: 5 = PC Board 7 KILOVAC High Voltage Relays Contact Arrangement -- K81A -- SPST-NO K81B -- SPST-NC Contact Form -- K81A -- A K81B -- B Test Voltage, DC or 60 Hz (Peak) -- 11 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 10 kV Continuous Carry Current, Max. -- DC or 60 Hz -- 5 A, 20 A or 30 A 1 Coil Hi-Pot (Vrms, 60 Hz) -- N/A Contact Resistance, Max. -- 0.03 ohm Operate Time, Max. -- 10 ms Release Time, Max. -- 10 ms Shock, 11ms, 1/2 Sine (Peak) -- 30 g Vibration -- Peak -- 10 g (55 to 500 Hz) 7 = Panel Mount PAGE 83 KILOVAC High Voltage Relays K81C Series Make & Break Load Switching -- 10 kV Relays Product Facts n SPDT version of K81 n Vacuum dielectric for power switching low current loads n Flying lead version will carry 10 Amps continuous current n PCB mount version will carry 5 Amps continuous current Product Specifications Contact Arrangement -- SPDT Contact Form -- C Test Voltage, DC or 60 Hz (Peak) -- 11 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 10 kV Continuous Carry Current, Max. -- DC or 60 Hz -- See Note 1 Coil Hi-Pot (Vrms, 60 Hz) -- N/A Contact Resistance, Max. -- 0.05 ohm Operate Time, Max. -- 10 ms Release Time, Max. -- 10 ms Shock, 11ms, 1/2 Sine (Peak) -- 30 g Vibration -- Peak -- 10 g (55 to 500 Hz) Operating Ambient Temperature Range -- -55C to +85C Mechanical Life -- 2 million cycles Weight, Nominal -- 70.87 g (2.5 oz.) Note: 1. 5 Amp carry for PC pin versions. 30 Amp carry for flying lead versions. Ordering Information Coil Data Volts, Nominal DC Pickup, Max. Dropout Coil Resistance (10%) 12 V 8 Vdc .5-5 Vdc 70 26.5 V 16 Vdc 1-10 Vdc 290 115 V 80 Vdc 5-50 Vdc 4700 Ratings listed are for 25C, sea level conditions Sample Part Number Series: Contact Form: C = SPDT Coil Voltage: 2 = 12 Vdc, PC Board 3 = 26.5 Vdc, PC Board 5 = 115 Vdc, PC Board For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS High Voltage Connections: 3 = PCB Solder Connection 4 = Flying Leads Mounting: 5 = PC Board K81 C 3 3 5 KILOVAC High Voltage Relays K43 Series Make & Break Load Switching -- 10 kV Relays K43A and K43B Product Facts for K43A and K43B n n n n n 10 kV, 25 Amps continuous current relay RF ratings to 32 MHz Vacuum dielectric for power switching low current loads 2 million cycle mechanical life QPL versions available, M83725/17 & M83725/10 K43C Product Facts for K43C n n n n n n SPDT version of K43 Vacuum dielectric for power switching low current loads Flange mounting available Carries 10 Amps at 32 MHz Meets requirements of MIL-R-83725 QPL version available, M83725/16 For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Product Specifications for K43A, K43B and K43C Coil Data Volts, Nominal DC Pickup, Max. Dropout Coil Resistance (10%) 12 V 8 Vdc .5-5 Vdc 70 26.5 V 16 Vdc 1-10 Vdc 290 115 V 80 Vdc 5-50 Vdc 4700 Ratings listed are for 25C, sea level conditions Ordering Information K43 A 3 3 4 Sample Part Number Series: Contact Form: A = SPST-NO B = SPST-NC C = SPDT Coil Voltage: 2 = 12 Vdc, Bus Wire 3 = 26.5 Vdc, Bus Wire 5 = 115 Vdc, Bus Wire 7 = 12 Vdc, Turret Terminal* 8 = 26.5 Vdc, Turret Terminal* 9 = 115 Vdc, Turret Terminal* *See page 7-87 for turret terminal dimensions and mounting methods. High Voltage Connections: 3 = Solder Connection Mounting*: 2 = Flanged 4 = Standard PAGE 85 7 KILOVAC High Voltage Relays Contact Arrangement -- K43A -- SPST-NO K43B -- SPST-NC K43C -- SPDT Contact Form -- K43A -- A K43B -- B K43C -- C Test Voltage, DC or 60 Hz (Peak) -- 11 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 10 kV 2.5 MHz -- 7 kV 16 MHz -- 6 kV 32 MHz -- 4 kV Continuous Carry Current, Max. -- DC or 60 Hz -- 25 A 2.5 MHz -- 20 A 16 MHz -- 13 A 32 MHz -- 10 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Capacitance -- Between Open Contacts -- 1.2 pF Open Contacts to Ground -- 1.2 pF Contact Resistance, Max. -- 0.02 ohm Operate Time, Max. -- 10 ms Release Time, Max. -- 10 ms Shock, 11ms, 1/2 Sine (Peak) -- 50 g Vibration -- Peak -- 10 g (55 to 2000 Hz) Operating Ambient Temperature Range -- -55C to +125C Mechanical Life -- 2 million cycles Weight, Nominal -- 28.35 g (1 oz.) KILOVAC High Voltage Relays K43 Series Make & Break Load Switching -- 10 kV Relays (Continued) KILOVAC K43P Make & Break Load Switching Product Facts for K43P n n n n n High power rating; 24 Amps DC continuous current carry Vacuum dielectric for power switching low current loads Low power consumption Fast operating: 5 millisecond operate time Meets requirements of MIL-R-83725 KILOVAC K43R Make & Break Load Switching Product Facts for K43R n n n n Single pole, double throw contacts with latching actuator Vacuum dielectric for power switching low current loads Carries 6 Amps at 32 MHz Meets requirements of MIL-R-83725 Product Specifications for K43P and K43R Contact Arrangement -- K43P -- SPST-Latching K43R -- SPDT-Latching Contact Form -- K43P -- P K43R -- R Test Voltage, DC or 60 Hz (Peak) -- 11 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 10 kV 2.5 MHz -- 7 kV 16 MHz -- 6 kV 32 MHz -- 4 kV Continuous Carry Current, Max. -- DC or 60 Hz -- 24 A 2.5 MHz -- 16 A 16 MHz -- 9 A 32 MHz -- 6 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Capacitance -- Between Open Contacts -- 1.2 pF Open Contacts to Ground -- 1.2 pF For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Contact Resistance, Max. -- 0.02 ohm Operate Time, Max. -- K43P -- 5 ms K43R -- 6 ms Release Time, Max. -- N/A Shock, 11ms, 1/2 Sine (Peak) -- 30 g Vibration -- Peak -- 7 g (55 to 2000 Hz) Operating Ambient Temperature Range -- -55C to +125C Mechanical Life -- 1 million cycles Weight, Nominal -- 28.35 g (1 oz.) Coil Data Volts, Nominal 26.5 Vdc Latch & Reset, Max. 16 Vdc Dropout N/A Coil Resistance (10%) 80 Ratings listed are for 25C, sea level conditions Ordering Information K43 P 3 3 4 Sample Part Number Series: Contact Form: P = SPST-Latching R = SPDT-Latching Coil Voltage: 3 = 26.5 Vdc, Bus Wire High Voltage Connections: 3 = Solder Connection *See page 7-87 for mounting methods. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Mounting: 2 = Flanged 4 = Standard KILOVAC High Voltage Relays H-14/16 Series Make & Break Load Switching -- 12 kV Relays H-14 Product Facts for H-14 n Double pole, double throw contacts n Vacuum dielectric for power switching low current loads n 30 Amps DC continuous current rating n Corona shield high voltage terminals available n Meets requirements of MIL-R-83725 H-16 Product Facts for H-16 n 12 kV rating; isolates 5 kV at 32 MHz n Vacuum dielectric for power switching low current loads n Double pole, double throw contacts n Widely used as a transmit/ receive switch n Meets requirements of MIL-R-83725 Product Specifications for H-14 and H-16 For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Coil Data Nominal Volts DC Pickup, Max. Dropout Coil Resistance (10%) 12 Vdc 8 Vdc .5-5 Vdc 24 26.5 Vdc 16 Vdc 1-10 Vdc 120 115 Vdc 80 Vdc 5-50 Vdc 2000 Ratings listed are for 25C, sea level conditions Ordering Information Sample Part Number H- 14 /12Vdc Series: Model: 14 16 Coil Voltage: Blank = 26.5 Vdc /12Vdc = 12 Vdc /115Vdc = 115 Vdc PAGE 87 7 KILOVAC High Voltage Relays Contact Arrangement -- DPDT Contact Form -- 2C Test Voltage, DC or 60 Hz (Peak) -- 15 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 12 kV 2.5 MHz -- 10 kV 16 MHz -- 8 kV 32 MHz -- 5 kV Continuous Carry Current, Max. -- DC or 60 Hz -- 30 A 2.5 MHz -- H-14 -- 15 A H-16 -- 10 A 16 MHz -- H-14 -- 10 A H-16 -- 6 A 32 MHz -- H-14 -- 8 A H-16 -- 4 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Capacitance -- Between Open Contacts -- 1 pF Open Contacts to Ground -- 2.5 pF Contact Resistance, Max. -- H-14 -- 0.015 ohm H-16 -- 0.03 ohm Operate Time, Max. -- 20 ms Release Time, Max. -- 20 ms Shock, 11ms, 1/2 Sine (Peak) -- 20 g Vibration -- Peak -- 10 g (55 to 500 Hz) Operating Ambient Temperature Range -- -55C to +125C Mechanical Life (Operations x 106) -- H-14 -- 1 million cycles H-16 -- 500,000 cycles Weight, Nominal -- H-14 -- 226.8 g (8 oz.) H-16 -- 170.1 g (6 oz.) KILOVAC High Voltage Relays H-8 Make & Break Load Switching -- 15 kV Relays Product Facts n Single pole, double throw contacts n Vacuum dielectric for power switching low current loads n 30 Amps DC continuous current rating n Corona shield high voltage terminals available n Meets requirements of MIL-R-83725 Product Specifications Contact Arrangement -- SPDT Contact Form -- C Test Voltage, DC or 60 Hz (Peak) -- 20 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 15 kV 2.5 MHz -- 12 kV 16 MHz -- 10 kV 32 MHz -- 5 kV Continuous Carry Current, Max. -- DC or 60 Hz -- 15 A RMS 2.5 MHz -- 10 A RMS 16 MHz -- 6 A RMS 32 MHz -- 4 A RMS Coil Hi-Pot (Vrms, 60 Hz) -- 500 A RMS Contact Capacitance -- Between Open Contacts -- 1 pF Open Contacts to Ground -- 1.5 pF Contact Resistance, Max. -- 0.015 ohm Operate Time, Max. -- 15 ms Release Time, Max. -- 15 ms Coil Data Volts, Nominal DC Pickup, Max. Dropout Coil Resistance (10%) For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS 12 V 8 Vdc .5-5 Vdc 60 26.5 V 16 Vdc 1-10 Vdc 265 115 V 80 Vdc 5-50 Vdc 3500 Shock, 11ms, 1/2 Sine (Peak) -- 30 g Vibration -- Peak -- 10 g (55 to 500 Hz) Operating Temperature Range -- -55C to +125C Mechanical Life -- 1 million cycles Weight, Nominal -- 85 g (3 oz.) KILOVAC High Voltage Relays KC Series Make & Break Load Switching -- 15 kV Relays KC-14 KC-18 Product Facts for KC-14 and KC-18 n n n n Specifically designed for load switching applications Can power switch and isolate loads Replaces KILOVAC KC-8 and KC-12 Meets requirements of MIL-R-83725 *Hot Switching, Resistive Load Life Product Specifications for KC-14 and KC-18 For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. *Ratings are for normally open contacts only. No testing has been performed on normally closed contacts. Coil Data Volts, Nominal DC Pickup, Max. Dropout Coil Resistance (10%) 12 V 8 Vdc .5-5 Vdc 48 26.5 V 16 Vdc 1-10 Vdc 180 115 V 80 Vdc 5-50 Vdc 2900 Ratings listed are for 25C, sea level conditions Ordering Information Sample Part Number KC- 18 /12Vdc Series: Model: 14 18 Coil Voltage: Blank = 26.5 Vdc /12Vdc = 12 Vdc /115Vdc = 115 Vdc PAGE 89 7 KILOVAC High Voltage Relays Contact Arrangement -- SPDT Contact Form -- C Test Voltage, DC or 60 Hz (Peak) -- 17 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 15 kV Continuous Carry Current, Max. -- DC or 60 Hz -- 30 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Capacitance -- Between Open Contacts -- 0.5 pF Open Contacts to Ground -- 1 pF Contact Resistance, Max. -- 0.025 ohm Operate Time, Max. -- 15 ms Release Time, Max. -- 9 ms Shock, 11ms, 1/2 Sine (Peak) -- 50 g Vibration -- Peak -- 10 g (55 to 500 Hz) Operating Ambient Temperature Range -- -55C to +125C Mechanical Life -- 1 million cycles Weight, Nominal -- 85 g (3 oz.) Load Life Voltage Current Operations 330 Vdc 17 Amps 10,000 330 Vdc 5 Amps 100,000 5,000 Vdc 2 Amps 100,000 10,000 Vdc 1 Amps 50,000 KILOVAC High Voltage Relays KC Series Make & Break Load Switching -- 15 kV Relays (Continued) KC-2 No Load Switching Product Facts n Vacuum dielectric for low and stable contact resistance n Carries 50 Amps at DC; 10 Amps at 32 MHz n Not designed for power switching KC-8 Product Facts for KC-8 n Not recommended for new design. See KC-14 on page 7-82 for replacement. KC-11 No Load Switching Product Facts n Threaded base version of KC-2 n Vacuum dielectric for low leakage current applications KC-12 Product Facts n Not recommended for new design. See KC-18 on page 7-67 for replacement. n Vacuum dielectric for power switching low current loads Product Specifications for KC-2, KC-8, KC-11 and KC-12 Contact Arrangement -- SPDT Contact Form -- C Test Voltage, DC or 60 Hz (Peak) -- 17 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 15 kV 2.5 MHz -- KC-2 and KC-11 -- 12 kV 16 MHz -- KC-2 and KC-11 -- 9 kV 32 MHz -- KC-2 and KC-11 -- 7 kV Continuous Carry Current, Max. -- DC or 60 Hz -- KC-2 and KC-11 -- 50 A KC-8 and KC-12 -- 30 A 2.5 MHz -- KC-2 and KC-11 -- 30 A 16 MHz -- KC-2 and KC-11 -- 17 A 32 MHz -- KC-2 and KC-11 -- 10 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Capacitance -- Between Open Contacts -- 0.5 pF Open Contacts to Ground -- 1 pF Contact Resistance, Max. -- KC-2 and KC-11 -- 0.012 ohm KC-8 and KC-12 -- 0.025 ohm Operate Time, Max. -- 15 ms Release Time, Max. -- 9 ms Shock, 11ms, 1/2 Sine (Peak) -- 50 g Vibration -- Peak -- 10 g (55 to 500 Hz) Operating Ambient Temperature Range -- -55C to +125C Mechanical Life -- 1 million cycles Weight, Nominal -- 85 g (3 oz.) For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Coil Data Nominal Volts DC Pickup, Max. Dropout Coil Resistance (10%) KC-2 and KC-11 KC-8 and KC-12 12 Vdc 8 Vdc .5-5 Vdc 26.5 Vdc 16 Vdc 1-10 Vdc 115 Vdc 80 Vdc 5-50 Vdc 60 48 250 180 3500 2900 Ratings listed are for 25C, sea level conditions Ordering Information KC- 2 /12Vdc Sample Part Number Series: Model: 2 8 Coil Voltage: Blank = 26.5 Vdc 11 /12Vdc = 12 Vdc 12 /115Vdc = 115 Vdc KILOVAC High Voltage Relays KC Series Make Only Load Switching -- 15 kV Relays (Continued) KC-15 Product Facts n n n n SF-6 gas-filled for power switching on the "make" Long load life in capacitive discharge Recommended for ESD testing and safety interlock applications Meets requirements of MIL-R-83725 KC-16 Product Facts n n n n Threaded base version of KC-15 SF-6 gas-filled for power switching on the "make" 15 kV rating Meets requirements of MIL-R-83725 Product Specifications for KC-15 and KC-16 Note: *Contact resistance for gas-filled relays measured 28 Vdc, 1 Amp Coil Data Volts, Nominal DC Pickup, Max. Dropout Coil Resistance (10%) 12 V 8 Vdc .5-5 Vdc 48 26.5 V 16 Vdc 1-10 Vdc 180 115 V 80 Vdc 5-50 Vdc 2900 Ratings listed are for 25C, sea level conditions 7 Ordering Information Sample Part Number KC- 15 /12Vdc Series: Model: 15 16 Coil Voltage: Blank = 26.5 Vdc /12Vdc = 12 Vdc /115Vdc = 115 Vdc For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. PAGE 91 KILOVAC High Voltage Relays Contact Arrangement -- SPDT Contact Form -- C Test Voltage, DC or 60 Hz (Peak) -- 17 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 15 kV Continuous Carry Current, Max. -- DC or 60 Hz -- 12 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Capacitance -- Between Open Contacts -- N/A Open Contacts to Ground -- N/A Contact Resistance, Max. -- 1.0 ohm* Operate Time, Max. -- 15 ms Release Time, Max. -- 9 ms Shock, 11ms, 1/2 Sine (Peak) -- 50 g Vibration -- Peak -- 10 g (55 to 500 Hz) Operating Ambient Temperature Range -- -55C to +125C Mechanical Life -- 1 million cycles Weight, Nominal -- 85 g (3 oz.) KILOVAC High Voltage Relays H-26 Series Make & Break Load Switching -- 15 kV Relays Product Facts n n n n Highly reliable four pole double throw relay Used to switch multiple loads and for polarity reversal Vacuum dielectric for power switching low current loads Meets requirements of MIL-R-83725 Product Specifications Contact Arrangement -- 4PDT Contact Form -- 4C Test Voltage, DC or 60 Hz (Peak) -- 17 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 15 kV 2.5 MHz -- 12 kV 16 MHz -- 10 kV 32 MHz -- 7 kV Continuous Carry Current, Max. -- DC or 60 Hz -- 30 A 2.5 MHz -- 10 A 16 MHz -- 6 A 32 MHz -- 4 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Capacitance -- Between Open Contacts -- 1 pF Open Contacts to Ground -- 2.5 pF Contact Resistance, Max. -- 0.02 ohm Operate Time, Max. -- 30 ms Release Time, Max. -- 30 ms Shock, 11ms, 1/2 Sine (Peak) -- 30 g Vibration -- Peak -- 10 g (55 to 500 Hz) Operating Ambient Temperature Range -- -55C to +125C Mechanical Life -- 100,000 cycles Weight, Nominal -- 340 g (12 oz.) Coil Data Volts, Nominal DC Pickup, Max. Dropout Coil Resistance (10%) 12 V 8 Vdc .5-5 Vdc N/A 26.5 V 16 Vdc 1-10 Vdc 130 115 V 80 Vdc 5-50 Vdc 2100 Ratings listed are for 25C, sea level conditions Ordering Information Sample Part Number Model: H-26 Coil Voltage: Blank = 26.5 Vdc /12Vdc = 12 Vdc /115Vdc = 115 Vdc For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS H-26 /12Vdc KILOVAC High Voltage Relays H-19/17 Series Make & Break Load Switching -- 20/25 kV Relays H-19 Product Facts n 20 kV operating voltage n Vacuum dielectric and tungsten contacts for power switching low current loads n Double pole, double throw contacts n Available with corona shield connectors n Meets requirements of MIL-R-83725 H-17 Product Facts n Will isolate 12 kV at 32 MHz n Tungsten contacts suitable for power switching low current loads n Available with corona shield connectors n Meets requirements of MIL-R-83725 n QPL version available, M83725/2 Product Specifications for H-19 and H-17 For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Coil Data Nominal Volts DC Pickup, Max. Dropout Coil Resistance (10%) H-19 H-17 12 Vdc 8 Vdc .5-5 Vdc 26.5 Vdc 16 Vdc 1-10 Vdc 115 Vdc 80 Vdc 5-50 Vdc 48 24 225 120 2100 2900 7 Ratings listed are for 25C, sea level conditions Ordering Information Sample Part Number H- 17 /12Vdc Series: Model: H-19 H-17 Coil Voltage: Blank = 26.5 Vdc /12Vdc = 12 Vdc /115Vdc = 115 Vdc PAGE 93 KILOVAC High Voltage Relays Contact Arrangement -- H-19 -- DPDT H-17 -- SPDT Contact Form -- H-19 -- 2C H-17 -- C Test Voltage, DC or 60 Hz (Peak) -- H-19 -- 25 kV H-17 -- 30 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- H -19 -- 20 kV H-17 -- 25 kV 2.5 MHz -- H-19 -- 15 kV H-17 -- 20 kV 16 MHz -- H-19 -- 10 kV H-17 -- 15 kV 32 MHz -- H-19 -- 7 kV H-17 -- 12 kV Continuous Carry Current, Max. -- DC or 60 Hz -- 30 A 2.5 MHz -- H-19 -- 18 A H-17 -- 16 A 16 MHz -- H -19 -- 9 A H-17 -- 10 A 32 MHz -- H -19 -- 6 A H-17 -- 8 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Capacitance -- Between Open Contacts -- 1 pF Open Contacts to Ground -- 2.5 pF Contact Resistance, Max. -- 0.015 ohm Operate Time, Max. -- H-19 -- 30 ms H-17 -- 25 ms Release Time, Max. -- H-19 -- 20 ms H-17 -- 25 ms Shock, 11ms, 1/2 Sine (Peak) -- H-19 -- 30 g H-17 -- 20 g Vibration -- Peak -- 10 g (55 to 500 Hz) Operating Ambient Temperature Range -- -55C to +125C Mechanical Life -- 1 million cycles Weight, Nominal -- H-19 -- 241 g (8.5 oz.) H-17 -- 198.4 g (7 oz.) KILOVAC High Voltage Relays K62 Series Make & Break Load Switching -- 25 kV Relays K62A and K62B Product Facts n n n 25 kV relay with flying leads for ease of installation Vacuum dielectric and tungsten contacts for power switching low current loads Meets requirements of MIL-R-83725 K62C Product Facts n n n n SPDT version of K62 Vacuum dielectric for power switching low current loads Carries 18 Amps continuous current Meets requirements of MIL-R-83725 Product Specifications for K62A, K62B and K62C Contact Arrangement -- K62A -- SPST-NO K62B -- STST-NC K62C -- SPDT Contact Form -- K62A -- A K62B -- B K62C -- C Test Voltage, DC or 60 Hz (Peak) -- 30 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 25 kV 20 g Vibration -- Peak -- 10 g (55 to 500 Hz) Operating Ambient Temperature Range -- -55C to +85C Mechanical Life -- 1 million cycles Weight, Nominal -- 340 g (12 oz.) Continuous Carry Current, Max. -- DC or 60 Hz -- 18 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Resistance, Max. -- 0.50 ohm Operate Time, Max. -- 15 ms Release Time, Max. -- 15 ms Shock, 11ms, 1/2 Sine (Peak) -- For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Coil Data Volts, Nominal DC Pickup, Max. Dropout Coil Resistance (10%) 12 V 9 Vdc .5-5 Vdc 30 26.5 V 18 Vdc 1-10 Vdc 125 115 V 90 Vdc 5-55 Vdc 2400 Ratings listed are for 25C, sea level conditions Ordering Information Sample Part Number K62 A 7 4 1 Series: Contact Form: A = SPST-NO B = SPST-NC Coil Voltage: 7 = 12 Vdc, Turret Terminal 8 = 26.5 Vdc, Turret Terminal 9 = 115 Vdc, Turret Terminal High Voltage Connections: 4 = Flying Leads, 12" 7 = Flying Leads, 72" 8 = Flying Leads, 36" Mounting: 1 = Threaded C = SPDT KILOVAC High Voltage Relays KC-Series No Load Switching -- 25 kV Relays KC-20 Product Facts n Rugged, high current carry ceramic relay n Carries 30 Amps at 32 MHz n Copper contacts; not designed for power switching n Meets requirements of MIL-R-83725 KC-30 Product Facts n Normally closed version of KC-20 n Carries 55 Amps DC n Vacuum dielectric for low leakage current applications Product Specifications for KC-20 and KC-30 For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Coil Data Volts, Nominal DC Pickup, Max. Dropout Coil Resistance (10%) 12 V 8 Vdc .5-5 Vdc 24 26.5 V 16 Vdc 1-10 Vdc 120 115 V 80 Vdc 5-50 Vdc 2000 Ratings listed are for 25C, sea level conditions 7 Ordering Information Sample Part Number KC- 20 /12Vdc Series: Model: KC-20 KC-30 Coil Voltage: Blank = 26.5 Vdc /12Vdc = 12 Vdc /115Vdc = 115 Vdc PAGE 95 KILOVAC High Voltage Relays Contact Arrangement -- KC-20 -- SPST-NO KC-30 -- SPST-NC Contact Form -- KC-20 -- X KC-30 -- Y Test Voltage, DC or 60 Hz (Peak) -- KC-20 -- 30 kV KC-30 -- 28 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- K C-20 -- 28 kV KC-30 -- 25 kV 2.5 MHz -- 22 kV 16 MHz -- KC-20 -- 12 kV KC-30 -- 10 kV 32 MHz -- KC-20 -- 10 kV KC-30 -- 9 kV Continuous Carry Current, Max. -- DC or 60 Hz -- KC-20 -- 110 A KC-30 -- 55 A 2.5 MHz -- KC-20 -- 60 A KC-30 -- 30 A 16 MHz -- K C-20 -- 40 A KC-30 -- 20 A 32 MHz -- K C-20 -- 30 A KC-30 -- 15 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Capacitance -- Between Open Contacts -- 2.5 pF Open Contacts to Ground -- 2.5 pF Contact Resistance, Max. -- KC-20 -- 0.005 ohm KC-30 -- 0.01 ohm Operate Time, Max. -- 18 ms Release Time, Max. -- KC-20 -- 10 ms KC-30 -- 20 ms Shock, 11ms, 1/2 Sine (Peak) -- 30 g Vibration -- Peak -- 10 g (55 to 500 Hz) Operating Ambient Temperature Range -- -55C to +125C Mechanical Life -- 2 million cycles Weight, Nominal -- 340 g (12 oz.) KILOVAC High Voltage Relays KC-Series -- 25 kV Relays KC-22, KC-32 Make & Break Load Switching Product Facts for KC-22 n Tungsten contacts for power switching Product Facts for KC-32 n n Normally closed version of KC-22 Vacuum dielectric for power switching low current loads KC-28, KC-38 Make Only Load Switching Product Facts for KC-28 n n SF-6 gas-filled for capacitive discharge and "make only" applications Capable of switching 2000 Amps peak capacitive discharge for 400 nanoseconds Product Facts for KC-38 n n Normally closed version of KC-28 SF-6 gas-filled for capacitive discharge and "make only" applications Product Specifications for KC-22, KC-32, KC-28 & KC-38 Contact Arrangement -- KC-22 and KC-28 -- SPST-NO KC-32 and KC-38 -- SPST-NC Contact Form -- KC-22 and KC-28 -- X KC-32 and KC-38 -- Y Test Voltage, DC or 60 Hz (Peak) -- 28 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 25 kV Continuous Carry Current, Max. -- DC or 60 Hz -- K C-22 -- 65 A KC-32 -- 45 A KC-28 -- 30 A KC-38 -- 15 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Capacitance -- Between Open Contacts -- KC-22 and KC-32 -- 2.5 pF Open Contacts to Ground -- KC-22 and KC-32 -- 2.5 pF Contact Resistance, Max. -- KC-22 -- 0.005 ohm KC-32 -- 0.01 ohm KC-28 -- 1.0 ohm* KC-38 -- 1.0 ohm* Operate Time, Max. -- 18 ms Release Time, Max. -- KC-22 and KC-28 -- 10 ms KC32 and KC-38 -- 20 ms Shock, 11ms, 1/2 Sine (Peak) -- 30 g Vibration -- Peak -- 10 g (55 to 500 Hz) Operating Ambient Temperature Range -- -55C to +125C Mechanical Life -- 2 million cycles Weight, Nominal -- 340 g (12 oz.) Coil Data Volts, Nominal DC Pickup, Max. Dropout Coil Resistance (10%) 12 V 8 Vdc .5-5 Vdc 24 26.5 V 16 Vdc 1-10 Vdc 120 115 V 80 Vdc 5-50 Vdc 2000 Ratings listed are for 25C, sea level conditions For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Ordering Information KC- 22 /12Vdc Sample Part Number Series: Model: KC-22 KC-32 Coil Voltage: Blank = 26.5 Vdc KC-28 /12Vdc = 12 Vdc KC-38 /115Vdc = 115 Vdc KILOVAC High Voltage Relays H-23/24 Series Make & Break Load Switching -- 30 kV Relay (Not recommended for new designs) Product Facts n n See K61 or K62 series for latest generation products Vacuum dielectric for power switching low current loads Product Specifications Contact Arrangement -- H-23 -- SPST-NC H-24 -- SPST-NO Contact Form -- H-23 -- B H-24 -- A Test Voltage, DC or 60 Hz (Peak) -- 35 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 30 kV 2.5 MHz -- 24 kV 16 MHz -- 18 kV 32 MHz -- 7 kV Continuous Carry Current, Max. -- DC or 60 Hz -- 30 A 2.5 MHz -- 20 A 16 MHz -- 12 A 32 MHz -- 7 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Capacitance -- Between Open Contacts -- N/A Open Contacts to Ground -- N/A Contact Resistance, Max. -- 0.015 ohm Operate Time, Max. -- 30 ms Release Time, Max. -- 20 ms Shock, 11ms, 1/2 Sine (Peak) -- 20 g Vibration -- Peak -- 10 g (55 to 500 Hz) Operating Ambient Temperature Range -- -55C to +125C Mechanical Life -- 1 million cycles Weight, Nominal -- 198.4 g (7 oz.) Coil Data Volts, Nominal DC Pickup, Max. Dropout Coil Resistance (10%) 12 V 8 Vdc .5-5 Vdc 24 26.5 V 16 Vdc 1-10 Vdc 120 115 V 80 Vdc 5-50 Vdc 2000 7 Ratings listed are for 25C, sea level conditions KILOVAC High Voltage Relays Ordering Information Sample Part Number H- 23 /12Vdc Series: Model: H-23 H-24 For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Coil Voltage: Blank = 26.5 Vdc /12Vdc = 12 Vdc /115Vdc = 115 Vdc PAGE 97 KILOVAC High Voltage Relays KP61 Series -- 35 kV Relays Product Facts n n n n n n SF-6 gas-filled relay is excellent for capacitive discharge applications Widely used in test equipment and medical instruments Fully operable in air and suitable for adverse environments Contact forms A, B & C 35 kV rating in compact, durable package Lower cost version of K61 series Product Specifications Contact Arrangement/Form -- SPST-NO / A SPST-NC / B SPDT / C Test Voltage, DC or 60 Hz (Peak) -- 40 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 35 kV Continuous Carry Current, Max. -- DC or 60 Hz -- 10 A Contact Resistance, Max. -- 1.0 Shock, 11ms, 1/2 Sine (Peak) -- 20 g Vibration -- Peak -- 10 g (55 to 500 Hz) Operating Ambient Temperature Range -- -55C to +85C Mechanical Life -- 1 million cycles Weight, Nominal -- 297.7g (10.5 oz.) Coil Data Volts, Nominal DC Pickup, Max. Dropout Coil Resistance (10%) 12 V 9 Vdc .5-5 Vdc 30 26.5 V 18 Vdc 1-10 Vdc 125 115 V 90 Vdc 5-50 Vdc 2000 Ratings listed are for 25C, sea level conditions Ordering Information Sample Part Number KP61 C 8 4 1 Series: Contact Form: A = SPST-NO B = SPST-NC Coil Voltage: 7 = 12 Vdc, Turret Terminal 8 = 26.5 Vdc, Turret Terminal 9 = 115 Vdc, Turret Terminal For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. High Voltage Connections: 4 = Flying Leads, 12" 5 = Flying Leads, 72" 6 = Flying Leads, 36" Mounting: 1 = Threaded AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS C = SPDT KILOVAC High Voltage Relays K60 Series Make Only Load Switching -- 35 kV Relays K60C (35 kV)* Product Facts n n 35 kV rating when operated in oil or potting Smallest 35 kV rated relay available *Customer must isolate high voltage terminals using suitable dielectric such as oil or potting Product Specifications Contact Arrangement -- SPDT Contact Form -- C Test Voltage, DC or 60 Hz (Peak) -- 37 kV** Rated Operating Voltage (Peak) -- DC or 60 Hz -- 35 kV** Continuous Carry Current, Max. -- DC or 60 Hz -- 10 A RMS Coil Hi-Pot (Vrms, 60 Hz) -- 500 A RMS Contact Resistance, Max. -- N/A Operate Time, Max. -- 15 ms Release Time, Max. -- 15 ms Shock, 11ms, 1/2 Sine (Peak) -- 20 g Vibration -- Peak -- 10 g (55 to 500 Hz) Operating Ambient Temperature Range -- -55C to +85C Mechanical Life -- 1 million cycles Weight, Nominal -- 93.6 g (3.3 oz.) Note: **37 kV test voltage, 35 kV operate voltage when operated in oil. 7 Volts, Nominal DC Pickup, Max. Coil Resistance (10%) 12 V 9 Vdc 30 26.5 V 18 Vdc 125 KILOVAC High Voltage Relays Coil Data 115 V 90 Vdc 2400 Ratings listed are for 20C, sea level conditions For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. PAGE 99 KILOVAC High Voltage Relays K61 Series Make Only Load Switching -- 35 kV Relays K61A and K61B Product Facts for K61A and K61B n n n SF-6 gas-filled relay excellent for capacitive discharge applications Widely used in test equipment and medical instruments Fully operable in air and suitable for adverse environments K61C Product Facts for K61C n n n 35 kV rating in compact, durable package SF-6 gas-filled relay excellent for capacitive discharge applications SPDT version of K61 Product Specifications for K61A, K61B and K61C Contact Arrangement -- K61A -- SPST-NO K61B -- STST-NC K61C -- SPDT Contact Form -- K61A -- A K61B -- B K61C -- C Test Voltage, DC or 60 Hz (Peak) -- 40 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 35 kV Continuous Carry Current, Max. -- DC or 60 Hz -- 10 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Resistance, Max. -- 1.0 ohm* Operate Time, Max. -- 15 ms Release Time, Max. -- 15 ms Shock, 11ms, 1/2 Sine (Peak) -- 20 g Vibration -- Peak -- 10 g (55 to 500 Hz) Operating Ambient Temperature Range -- -55C to +85C Mechanical Life -- 1 million cycles Weight, Nominal -- 340 g (12 oz.) Note: *Contact resistance for gas-filled relays measured at 28 Vdc, 1 Amp For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Coil Data Volts, Nominal DC Pickup, Max. Dropout Coil Resistance (10%) 12 V 9 Vdc .5-5 Vdc 30 26.5 V 18 Vdc 1-10 Vdc 125 115 V 90 Vdc 5-50 Vdc 2000 Ratings listed are for 25C, sea level conditions Ordering Information Sample Part Number K61 A 7 4 1 Series: Contact Form: A = SPST-NO B = SPST-NC Coil Voltage: 7 = 12 Vdc, Turret Terminal 8 = 26.5 Vdc, Turret Terminal 9 = 115 Vdc, Turret Terminal High Voltage Connections: 4 = Flying Leads, 12" 7 = Flying Leads, 72" 8 = Flying Leads, 36" Mounting: 1 = Threaded C = SPDT KILOVAC High Voltage Relays K64 & H-25 Series -- 50 kV Relays K64C Make Only Load Switching Product Facts for K64C n n n SF-6 gas-filled relay ideal for high voltage isolation or "make only" power switching 50 kV rating in compact package High voltage leads and encapsulation allow full operation in air H-25 Make & Break Load Switching Product Facts for H-25 n n Vacuum relay provides low contact resistance Vacuum dielectric for power switching low current loads Product Specifications for K64C and H-25 For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Note: *Contact resistance for gas-filled relays measured at 28 Vdc, 1 Amp Coil Data Nominal Volts DC Pickup, Max. Dropout Coil Resistance (10%) K64C 26.5 Vdc 18 Vdc 1-10 Vdc 80 H-25 26.5 Vdc 16 Vdc 1-10 Vdc 120 Ratings listed are for 25C, sea level conditions 7 Ordering Information Sample Part Number K64 C 8 4 1 Series: Contact Form: C = SPDT Coil Voltage: 8 = 26.5 Vdc, Turret Terminal High Voltage Connections: 4 = Flying Leads, 12" 7 = Flying Leads, 72" 8 = Flying Leads, 36" Mounting: 1 = Threaded PAGE 101 KILOVAC High Voltage Relays Contact Arrangement -- SPDT Contact Form -- C Test Voltage, DC or 60 Hz (Peak) -- K64C -- 55 kV H-25 -- 60 kV Rated Operating Voltage (Peak) -- DC or 60 Hz -- 50 kV Continuous Carry Current, Max. -- DC or 60 Hz -- K 64C -- 10 A H-25 -- 30 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Resistance, Max. -- K64C -- 1.0 ohm* H-25 -- 0.015 ohm Operate Time, Max. -- K64C -- 15 ms H-25 -- 60 ms Release Time, Max. -- K64C -- 15 ms H-25 -- 60 ms Shock, 11ms, 1/2 Sine (Peak) -- K64C -- 10 g H-25 -- 15 g Vibration -- Peak -- 10 g (55 to 500 Hz) Operating Ambient Temperature Range -- -55C to +85C Mechanical Life -- K64C -- 1 million cycles H-25 --500,000 cycles Weight, Nominal -- K64C -- 340 g (12 oz.) H-25 -- 850.5 g (30 oz.) KILOVAC High Voltage Relays K70 Series Make Only Load Switching -- 70 kV Relays K70A and K70B Product Facts n n n n New, small, compact 70 kV relay package SF-6 gas-filled for capacitive discharge and high voltage isolation applications Suitable for charging and discharging of high voltage capacitors Safe for use in adverse environments K70C Product Facts n n n SPDT version of K70A SF-6 gas-filled for capacitive discharge and high voltage isolation applications Suitable for charging and discharging of high voltage capacitors Product Specifications for K70A, K70B and K70C Contact Arrangement -- K70A -- SPST-NO K70B -- SPST-NC K70C -- SPDT Contact Form -- K70A -- A K70B -- B K70C -- C Test Voltage, DC or 60 Hz (Peak) -- 75 kV Rated Operating Voltage (Peak) -- DC -- 70 kV 60 Hz RMS -- 30 kV Continuous Carry Current, Max. -- DC or 60 Hz -- 10 A Coil Hi-Pot (Vrms, 60 Hz) -- 500 A Contact Capacitance -- Between Open Contacts -- N/A Open Contacts to Ground -- N/A Contact Resistance, Max. -- 2.0 ohm* Operate Time, Max. -- 20 ms Release Time, Max. -- 15 ms Shock, 11ms, 1/2 Sine (Peak) -- 20 g Vibration -- Peak -- 10 g (55 to 500 Hz) Operating Ambient Temperature Range -- 0C to +85C Mechanical Life --500,000 cycles Weight, Nominal -- 510.3 g (18 oz.) Coil Data Volts, Nominal 26.5 Vdc Pickup, Max. 22 Vdc Dropout 1-10 Vdc Coil Resistance (10%) 75 Ratings listed are for 25C, sea level conditions Ordering Information Sample Part Number Note: *Contact resistance for gas-filled relays measured at 28 Vdc, 1 Amp For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS K70 A 8 4 1 Series: Contact Form: A = SPST-NO B = SPST-NC Coil Voltage: 8 = 26.5 Vdc, Turret Terminal High Voltage Connections: 4 = Flying Leads, 12" 7 = Flying Leads, 72" 8 = Flying Leads, 36" Mounting: 1 = Threaded C = SPDT KILOVAC High Voltage Relays Mounting Methods KILOVAC "stacked ceramic" series relays can be easily mounted in any of the several ways shown below. The relay base should be mounted to a ground Optional Coil Turret Terminals for PD5, PD10; K41, K43 Types Figure 1. potential for high voltage applications. KILOVAC relays are not position sensitive and can be mounted in any orientation. Standard Flange Mounting Figure 2. Optional Flange Mounting for PD5, PD10; K40, K41, K43 and K45 types Figure 4. Optional Flange Mounting for K44 Figure 3. Spring Clip Mounting Figure 5.Seastrom Manufacturing (800/447-3927 or 208/737-4300) Part Number 4502-53-50-2N or sim- Strap Mounting KILOVAC High Voltage Relays For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. 7 Figure 6.Adel Fasteners 9320010 (stainless & silicone) 9320002 (carbon steel & neoprene) PAGE 103 KILOVAC High Voltage Relays Special Connectors A number of KILOVAC relays are available with special, anti-corona high voltage connectors. Refer to the chart to determine if high voltage connectors are available for your model relay. These connectors can be ordered separately, by part number, or at the same time you order your relays (for "H: relays only) by simply adding the letter "C" to the part number. For instance, if you wish to purchase an H-8 relay with special connectors, you should order an "H-8C". If you already have an H-8, you can order three Part Number 0510 connectors and install them yourself by removing the standard solder lugs and carefully installing the connectors so as not to damage the glassto-metal seals. Optional High Voltage Connectors Relay Model H-8 H-14 H-16 H-19 H-26 Connector Part Number 0510 H-17 H-23 H-24 1886 EV250-1A EV250-1B EV250-2A EV250-2B EV250-8A EV250-8B 2005 EV250-5A 2625 KC-2, KC-8 KC-11, KC-12 KC-15, KC-16 KC-14, KC-18 6822 Connectors for EV250-1A, 1B, 2A & 2B TE supplies a connector with 7 leads attached. Order Part Number 2005, Part Number 1618004-1. For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS KILOVAC High Voltage Relays Special Connectors (Continued) Standard Lug Connectors Relay Model Connector Part Number H-18 0575 H-17 1447 KM-13 6810 H-14 H-16 H-19 H-26 8488 AC Coil Operation All TE KILOVAC relays are supplied with a DC coil. If you wish to operate the relay with AC, you may order a bridge rectifier as Part Number 0260. Bus Bar Connector Option for EV, LEV, CAP and MAP Products .900 (22.9) .250 (6.3) O .386 (9.8) 7 KILOVAC High Voltage Relays 2.26 (57.4) 1.460 (37.1) O .250 (6.3) 2XR .25 (6.3) O .70 (17.78) 45 x .06 Chamfer For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. PAGE 105 KILOVAC High Voltage Relays Application Notes for EV/LEV Contactors Introduction - Product Capabilities and Typical Applications TE KILOVAC EV and LEV contactors are designed to be the highest performance, smallest and lightest weight, sealed High Voltage contactors in the industry. With current carrying capability of up to 500A and power switching up to 200kW, they are used in a variety of industrial, marine, automotive, and commercial applications. Primarily designed to switch resistive loads,they can be used in a variety of circuit applications bearing in mind a few important considerations. This application note focuses on a few of the more common circuit configurations, and what to consider when selecting, installing and using the contactors. 1. Installation EV/LEV contactors can be mounted in any orientation, and due to the nature of their hermetic seal and isolated enclosure, can be mounted in close proximity to other equipment. However, care must be taken with regard to the termination of the power cables to the main terminals. It is important that the main power connection lugs are mated directly to the terminal seats. Be sure that the hardware stackup is in the proper order, and that washers and other spacers are not placed between the lug and terminal seat. Extraneous connection resistance can cause considerable power dissipation and terminal heating at high current carry. Refer to Figure 1 and Table I for the recommended hardware stackup and torque. Bolt Conductors Lock Washer Flat Washer Lug Lug Thread Engagement Terminal Figure11 Figure Main Main Terminal Terminal Hardware Hardware Installation Table I THREAD ENGAGEMENT(turns) Less than 5 5 TO 7 7 TO 8 8 TO 11 Mounting Feet (all) TORQUE Use longer fastener 7.9 Nm (70 in-lb) MAX 9.0 Nm (80 in-lb) MAX 9.0 Nm (80 in-lb) 11 Nm (100 in-lb) MAX 1.7-3.3 Nm (30-35 in-lb) Table I Use the same guidelines and torque maximum values for stud terminal contactors as well. AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS 2. Coils, Drive Circuits and Coil Economizing Since the power required to close the contacts is generally much greater than the required holding power, many KILOVAC contactors can be packaged with low-profile coils that utilize either an electronic economizer (switchmode PWM), or mechanical cut-throat economizer. The economizer lets-through the higher power required for contact closure, then reduces the power for holding, greatly reducing the coil power consumption and heating. These circuits are packaged with the contactor, and in most cases include coil suppression components as well. For customers who wish to provide their own circuitry, TE can provide suggestions for driving the coils of all versions of contactors. Single coil, uneconomized products are also available in the LEV product line. These coils are designed to operate at nominal power over all specified voltage and temperature ranges withouteconomizing circuitry. DC Coils up to 400Vdc and AC coils with integrated converters are available up to 240Vac. 3. Load Types and Power Switching Recommendations In general, all EV/LEV contactors are designed primarily for connection and interruption of resistive loads and slightly inductive loads (L/R<1ms). High currents (up to 2000A) can be interrupted in case of circuit faults, and high continuous currents upwards of 500A can be maintained through closed contacts. Some important points to consider are: a. Closing into current spikes due to uncharged filter capacitors. Capacitors should be pre-charged whenever possible to avoid excessive contact erosion and nuisance welds. Keep inrush current spikes below 650A at all times. Care should also be taken when considering other high-inrush loads such as lamps or motors. b. Large current spikes through closed contacts. Large current spikes through closed contacts in excess of 3000A can sometimes cause spot welding or contact levitation. c. Circuit inductance. Contactor break-arcs generally last as long as it takes to dissipate the stored inductive energy of the load (t (arc) = 1.1*L/R). Longer arcs due to circuit inductance can accelerate Bolt contact wear, and in Conductors extreme cases, can cause contactor Lock Washer failure. TE recommends that the time constant of the load be less than 1ms for safe operation and maximum life. Flat Washer Lug Contactor life is a function of the power level switched. Lug Thread Higher make/break currents erode contact materials Engagement Terminal faster and accelerate loss of dielectric withstanding between the open contacts. Figure 2 can be used as a guideline for estimating product life at a given load. Figure 1 Main Terminal Hardware Installation Main Terminal Hardware Installation KILOVAC High Voltage Relays Application Notes for EV/LEV Contactors (Continued) For applications requiring larger conductors than can practically be installed with single 4/0 AWG cable and lugs, adapter buss extensions can be obtained from TE. 5. Auxiliary Circuits Auxiliary contacts are available on most models. Configurations available are: SPST-NO, SPST-NC and SPDT. Auxiliary contacts are rated at 125Vac/ 1A or 30Vdc/3A. Contacts with gold plating for low level loads are also available. For circuit voltage below 10V/0.1A, gold contacts are recommended. Figure Figure2 2 Life Cycles Switched Life Cycles vs. vs.Power Power Switched 4. Recommended Conductor Sizes for Conductors Continuous Current Carry Bolt Lock Washer Many sources exist for recommending the proper Flat Washer conductor size for a given current carry. Many Lugof these Lug sources are concerned primarily with wire insulation Thread safety issues. Cable bundling, conduit types, length of Engagement Terminal runs, etc., are all important considerations. With regard to a contactor placed in line with the conductors, it is important to make sure that the wire size is sufficient such that the contactor terminals themselves do not overheat, leading to a failure of the Figure 1 device. In most cases, Terminal Hardware Installation the primary pathMain for removal of heat from the contactor terminals is the conductors themselves. Convection to atmosphere and conduction via the base mountings play a lesser role in this type of contactor due to the nature of the construction. TE has performed basic characterization of many of the styles of contactors discussed herein, and the data is presented in Figure 3. The recommended maximum power terminal temperature for all EV/LEV contactors is 150 C continuous and 175 C for 1 hour. The auxiliary contact actuating method will indicate the true position of the main contacts. The auxiliary contact actuation is directly coupled to the main contact moving bridge, and will not indicate "open" unless both contact gaps of the double-make, Form X contact are fully disconnected. Keep in mind that the auxiliary contact is mainly a status indication, and should not be used to directly power other loads such as a relay coil or high power lamp load. 6. Environmental Considerations Figure 3 All KILOVAC contactors are characterized for operation Recommended Conductor Sizes in thermal, vibration, moisture and fluid environments. Consult the appropriate data sheet for limits concerning shock, vibration, temperature range and altitude limits. In some cases, there may be variations in limits with regard to "specified operation" or "survival only". 7. Custom Configurations Most parts can be ordered with a variety of combinations of main terminal and coil configurations, auxiliary contacts, interface connectors, coil voltages, etc. If you have a requirement for a particular configuration not shown on the data sheet, consult the factory for information regarding custom configurations. 8. Summary This Application Note is meant to address some of the more common questions regarding the use of EV/LEV contactors. In all cases, please refer to the applicable product data sheet for specific information. Also, Product Application Engineers are available to answer questions regarding these products by calling 800-253-4560 x2055, or 805-220-2055. 7 KILOVAC High Voltage Relays Figure Figure 33 Recommended Conductor Sizes Sizes Recommended Conductor PAGE 107 KILOVAC High Voltage Relays Application Notes for MAP/CAP Contactors Introduction - Product Capabilities And Typical Applications TE KILOVAC MAP/CAP contactors are designed to be the highest performance, smallest and lightest weight, sealed High Voltage contactors in the industry. With current carrying capability of up to 500A and power switching up to 200kW, they are used in a variety of commercial aerospace and military applications. Primarily designed to switch resistive loads, they can be used in a variety of circuit applications bearing in mind a few important considerations. This application note focuses on a few of the more common circuit configurations, and what to consider when selecting, installing and using the contactors. 1. Installation TE KILOVAC MAP/CAP contactors can be mounted in any orientation, and due to the nature of their hermetic seal and isolated enclosure, can be mounted in close proximity to other equipment. However, care must be taken with regard to the termination of the power cables to the main terminals. It is important that the main power connection lugs are mated directly to the terminal seats. Be sure that the hardware stackup is in the proper order, and that washers and other spacers are not placed between the lug and terminal seat. Extraneous connection resistance can cause considerable power dissipation and terminal heating at high current carry. Refer to Figure 1 and Table I for the recommended hardware stackup and torque. Conductors Thread Engagement Lock Washer Flat Washer Lug Lug Terminal Figure Figure11 MainTerminal TerminalHardware HardwareInstallation Installation Main Lock Washer Flat Washer Lug Lug tion ntage widest , EMC a. Single Thread Coil requiring Engagement THREAD TORQUE ENGAGEMENT(turns) Table II Less than 5 Coil Configurations Use longer fastener 5 TO 7 7.9 Nm (70 in-lb) MAX 7 TO 8 9.0 Nm (80 in-lb) MAX Type Advantage 8 TO 11 9.0 Nm (80 in-lb) Electronic PWM Operates over widest 11 Nm (100 in-lb) MAX voltageNm range Mounting Feet (all) 1.7-3.3 (30-35 in-lb) Electronic CT Simple, Robust, EMC TableCompliant I Mechanical CT Simple, robust, fastest operate time UseSingle the same maximum values Coil - guidelines and torque Flexibility, lower initial costfor stud terminaleconomized) contactors as well. (customer 2. Coils, Drive Circuits and Coil Economizing AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Lug Lug customer economizer circuit Terminal b. Single Coil with supplied electronic economizer c. Dual Coil with supplied mechanical "cut-throat" economizer Figure 1 d. Dual Coil withMain supplied electrical "cut-throat" economizer Terminal Hardware Installation The advantages of each type of coil circuit are shown in Table II. Table II Coil Configurations Type Electronic PWM Electronic CT Bolt Bolt Terminal Since the power required to close the contacts is generally much greater than the required holding power, many contactors can be packaged with low-profile coils that utilize either an electronic economizer (switchmode PWM, electronic cut-throat), or mechanical cutthroat economizer. The economizer lets-through the higher power required for contact closure, then reduces the power for holding, greatly reducing the coil power consumption and heating. These circuits are packaged with the contactor, and in most cases include coil suppression components as well. For Bolt Conductors customers who wish to provide their own circuitry, TE can provide suggestions for driving the coils ofLock all versions of Washer Flat Washer contactors. Four types of actuators are typically used: Mechanical CT Advantage Operates over widest voltage range Simple, Robust, EMC Compliant Simple, robust, fastest operate time TORQUE Flexibility, lower initial cost SingleTHREAD Coil ENGAGEMENT(turns) (customer economized) Less than 5 Use longer fastener 5 TO 7 7.9 TableNm II (70 in-lb) MAX 7 TO 8 9.0 Nm (80 in-lb) MAX Coil Configurations 8 TO 11 9.0 Nm (80 in-lb) 11 Nm (100 in-lb) MAX 3. Load TypesFeet and (all) Power Switching Mounting 1.7-3.3Recommendations Nm (30-35 in-lb) In general, all MAP/CAP contactors are designed primarily for connection and interruption of resistive loads and slightly inductive loads (L/R<1ms). High currents (up to 2000A) can be interrupted in case of circuit faults, and high continuous currents upwards of 500A can be maintained through closed contacts. Some important pints to consider are: a. Closing into current spikes due to uncharged filter capacitors. Capacitors should be pre-charged whenever possible to avoid excessive contact erosion and nuisance welds. Keep inrush current spikes below 650A at all times. Care should also be taken when considering other high-inrush loads such as lamps or motors. THREAD ENGAGEMENT(tur Less than 5 5 TO 7 7 TO 8 8 TO 11 Mounting Feet (all) KILOVAC High Voltage Relays Conductors Application Notes Bolt for MAP/CAP Contactors (Continued) Lock Washer Bolt Large b. L arge current spikes through closed contacts. Flat Washer Conductors Lug current spikes through closed contacts in excess of Lock Washer Lug 3000A can sometimes cause spot welding or contact Flat Washer Thread Engagement Lug Terminal levitation. Consult with the factory if your application Lug requires passing Thread large current pulses. Many contactors can be ordered with "Dual Contact" arrangements Engagement Terminal (Arcing contacts of harder material in parallel with high current carry material). Figure 1 Main Terminal Hardware Installation c. Circuit inductance. Contactor break-arcs generally Figure 1 Main Terminal Hardware last as long as it takes to dissipate theInstallation stored inductive energy of the load (t (arc) = 1.1*L/R). Table II Coil Configurations Longer arcs due to circuit inductance can accelerate Table IIcan cause contactor contact wear, and in extreme cases, TypeCoil Configurations Advantage failure. TE recommends that the time constant of the load Electronic PWM Operates over widest be less than 1ms for safe operation and maximum voltage range life. Type Electronic CT Electronic PWM Advantage Simple, Robust, EMC Operates over widest Compliant Contactor life is a function of the power level switched. voltage range robust, Mechanical CT Simple, fastest Higher make/break contact materials Electronic CTcurrents erodeSimple, Robust, EMC operate time Compliant faster and accelerate loss of dielectric withstanding Single Coil Flexibility, lower initial cost Mechanical CT economized) fastestas a (customer between the open contacts. FigureSimple, 2 canrobust, be used operate time guideline for estimating product life at a given Single Coil Flexibility, lowerload. initial cost THREAD TORQUE 4. Recommended Conductor Sizes for Continuous Current Carry ENGAGEMENT(turns) than 5 exist for recommending Use longer fastener Many Less sources the proper TORQUE 5THREAD TO 7size for a given7.9 Nm (70carry. in-lb) MAX conductor current Many of these ENGAGEMENT(turns) 7 TO 8 9.0 Nm (80 in-lb) MAX Less thanare 5 concerned Useprimarily longer fastener sources with wire insulation 8 TO 11 9.0 Nm (80 in-lb) 5 TO 7 issues. Cable bundling, 7.9 Nm safety conduit 11(70 Nmin-lb) (100MAX in-lb)types, MAX length of 7 TO 8Mounting Feet (all) 9.0 Nm (80 in-lb) Nm MAX (30-35 in-lb)With regard runs, etc., are all important1.7-3.3 considerations. 8 TO 11 9.0 Nm (80 in-lb) to a contactor placed 11 in Nm line(100 with theMAX conductors, it is in-lb) important to make sure thatNm the wirein-lb) size is sufficient Mounting Feet (all) 1.7-3.3 (30-35 such that the contactor terminals themselves do not overheat, leading to a failure of the device. In most cases, the primary path for removal of heat from the contactor terminals is the conductors themselves. Convection to atmosphere and conduction via the base mountings play a lesser role in this type of contactor due to the nature of the construction. TE has performed basic characterization of many of the styles of contactors discussed herein, and the data is presented in Figure 3. The recommended maximum power terminal temperature for all MAP/CAP contactors is 150 C continuous and 175 C for 1 hour. (customer economized) Longer arcs due to circuit inductance can accelerate contact wear, and in extreme cases, can cause contactor failure. TE recommends that the time constant of the load be less than 1ms for safe operation and maximum life. Contactor life is a function of the power level switched. Higher make/break currents erode contact materials faster and accelerate loss of dielectric withstanding between the open contacts. Figure 2 can be used as a guideline for estimating product life at a given load. Figure 3 Recommended Conductor Sizes For applications requiring larger conductors than can practically be installed with single 4/0 AWG cable and lugs, adapter buss extensions can be obtained from TE. PAGE 109 7 KILOVAC High Voltage Relays Figure 2 Life Cycle vs. Power Switched 5. Auxiliary Circuits Auxiliary contacts are available on most models. Configurations available are: SPST-NO, SPST-NC and SPDT. Auxiliary contacts are rated at 125Vac/ 1A or 30Vdc/3A. Contacts with gold plating for low level loads are also available. For circuit voltage below 10V/0.1A, gold contacts are recommended. The auxiliary contact actuating method will indicate the true position of the main contacts. The auxiliary contact actuation is directly coupled to the main contact moving bridge, and will not indicate "open" unless both contact gaps of the double-make, Form X contact are fully disconnected. Keep in mind that the auxiliary contact is mainly a status indication, and should not be used to directly power other loads such as a relay coil or high power lamp load. KILOVAC High Voltage Relays Application Notes for MAP/CAP Contactors (Continued) 6. Environmental Considerations All TE KILOVAC contactors are characterized for operation in thermal, vibration, moisture and fluid environments. Consult the appropriate data sheet for limits concerning shock, vibration, temperature range and altitude limits. In some cases, there may be variations in limits with regard to "specified operation" or "survival only". 7. Custom Configurations Most parts can be ordered with a variety of combinations of main terminal and coil configurations, auxiliary contacts, interface connectors, coil voltages, etc. If you have a requirement for a particular configuration not shown on the data sheet, consult the factory for information regarding custom configurations. 8. Summary This Application Note is meant to address some of the more common questions regarding the use of MAP/CAP contactors. In all cases, please refer to the applicable product data sheet for specific information. Also, Product Application Engineers are available to answer questions regarding these products by calling 800-253-4560 x2055, or 805-220-2055. Application Notes on Coil Power Economizing using PWM Circuits Introduction - Reducing Coil Power Dissipation through the use of PWM Circuits In the circuit shown, the "Fast Dropout" (FDO) and PWM driver are energized simultaneously for a sufficient time to allow the contacts to fully close. The PWM driver is then modulated such that the stored coil energy is utilized during the PWM driver "OFF" time to circulate holding current through the FDO driver and freewheeling diode. Since the holding current is much lower than the current required for pickup, the holding power for the contacts is greatly reduced. 1. Typical PWM Coil Drive Circuit Figure 1 shows a typical PWM coil drive/economizer circuit. The Fast Dropout circuit allows for the switching in/out of the "free-wheeling" diode. When power is removed, the FDO and PWM drivers will turn off, causing the stored energy of the coil to be rapidly dissipated in the body diodes. This minimizes the decay time of the coil current and facilitates a fast opening of the relay contacts. The coil power of most TE KILOVAC Relays and Contactors can be reduced after Pickup by using several economizing schemes. One of the most popular methods used in many of our standard products, and one that is suitable for implementation by customers, is the Pulse Width Modulated (PWM) coil driver. PWR Coil Relay Coil Coil_RTN Drive_FDO Body Diode Fast Drop Out Coil Current Return During PWM "ON" Free-w heeling Diode Coil Current Return During PWM "OFF" Drive_PWM Pickup Pulse PW M PWM RTN Fast Drop-out FET stays on during operation. FDO and Power can be applied simultaneously Filtering/Protection should be applied to FET gates as required. For higher energy coils, additional TVS protection may be required across FET drain-to-source. Figure 1 Coil Drive Circuit AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS Body Diode KILOVAC High Voltage Relays Application Notes on Coil Power Economizing using PWM Circuits (Continued) This fast opening is useful for circuit interruption, and it allows the over travel mechanism of the contact actuator to work effectively in breaking minor contact welds that may occur when closing the contacts. Allowing the free-wheeling diode to remain across the coil would significantly increase the contact opening time and opening speed, and possibly result in nuisance contact welds and/or reduced capability to interrupt circuit currents. If additional diodes are required to protect the FET body diodes, select a Transient Voltage Suppressor (TVS) diode with a breakdown rating lower than that of the driver FET body diode. In general, a higher voltage TVS diode will result in faster contact opening and higher clamping voltage, while a lower voltage TVS diode will result in slower contact opening and lower clamping voltage. For more detailed information regarding TVS diode selection, contact TE and request the report titled DC Relay Magnetic Energy Determination and Transient Voltage suppressor Diode Selection. Contact TE regarding the minimum required hold current needed for a particular Part Number. In general, divide the specified dropout voltage by the coil resistance at 20C, and add 25% above that to get an estimate of the value to use in equation (1) for Ihold. 2.0 Summary This Application Note is meant to address some of the more common questions regarding the use of PWM circuits for coil power economization. In all cases, please refer to the applicable product data sheet for specific information. TE can also recommend alternative solutions for mechanical dual-coil economizers, as well as "Electronic Cut-Throat" economizers. Product Application Engineers are available to answer questions regarding this subject by calling 800-253-4560 x2055, or 805-220-2055. 1.1 Recommended Operating Frequency and Duty Cycle The frequency at which the PWM circuit is operated should be high enough such that the oscillation of the coil current does not lead to audible noise being generated by the magnetic components and coil winding. For most KILOVAC contactors, a coil drive frequency > 15 kHz is usually sufficient to ensure that nuisance audible noise is not generated. The PWM duty cycle required for economizing power while maintaining sufficient holding force can be calculated from the required holding current as follows: Duty Cycle(%) = (Ihold*R(T)Coil/Vsource)*100 (1) Where: R(T) = Coil Resistance at Temperature Ihold = Required Holding Current Vsource = Source Voltage 7 KILOVAC High Voltage Relays PAGE 111 KILOVAC High Voltage Relays and Contactors Engineering Notes AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS