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Features:
Kilovac EV500 "BUBBA" - 600 Amps Make & Break Load Switching
Very high power sealed contactor
Hydrogen dielectric for power switching high
current loads
Excellent for safety disconnect and transfer
switch applications
Ideal for circuit protection control
Hermetically "super-sealed" environment
uniquely protects contacts and all moving
parts; can operate in harsh environments
600-1000A continuous carry, dependent on
temperature and conductors used
3,300 A interrupt, 1,000 A make, @320 Vdc
12 and 24 volt coil control options. Call
factory for custom options
360 kW power switch capable
200oC hot power terminals capable
Bi-directional power switching
Note: Dimensions in inches. Multiply values by 25.4 for dimensions in mm. Features:
Auxiliary contacts optional
ELECTRICAL LIFE CYCLES vs POWER SWITCHING Built-in dual power coil economizer
8W holding typical
E V 5 0 0 R A T E D R E S IS T IV E H O T S W IT C H L IF E
Versatile power, voltage, and current
100000 operating range 320-1800Vdc *
M o m e n t a ry C o n ta c t
C a rry R e g io n L e v it a tio n ,
O p e ra tio n
P ro h ib ite d
10000
ELECTRICAL LIFE (CYCLES)
270 V dc
Preferred Polarity
1000
M a x . B re a k C u rre n t
320V 3300A
400 V dc
270V 3400A
115V 3600A
100
28V 4000A 900 V dc
10
1 10 100 1000 10000 100000
C U R R E N T (A M P S )
(re s is tiv e lo a d , m a k e a n d b re a k )
* Failure Mode: Dielectric withstand voltage test @ 2000Vdc, power terminal to terminal, leakage exceeds 1.0 mA.
PRODUCT SPECIFICATIONS
Part Number UNIT EV500 COIL DATA
Parameter 12V 24V Units
Contact Arrangement with: Form X SPST-NO
Type Driver 2 coil electronic
Auxiliary Contacts ................................................................ Form A SPST-NO
Rated Resistive Load @ 270 Vdc, 85oC (continuous/10 sec.) ... Voltage* (nominal ) 12 24 Vdc
A 600/1,600
Current Carry, Max. continuous, 25oC 2 .................................................. A 750 Pickup (close), max. 9.9 19.7
Overload Current @ 320 Vdc, Max. ................................... Hold, min. 9 18
Make (Closed into) ......................................................... A 1,000 Dropout (open), min. 2 4
Break (Open) ................................................................... A 3,300 Current (@VsNom/ 25oC)
Contact Resistance, Max. ................................................... ohms 0.0002 Inrush 3.3 A
1.7
Dielectric at Sea Level (leakage < 1mA) A
Holding, standby 0.74 0.37
Open Power Terminal to Terminal ................................ Vrms 2,000 Inrush Time, max. 300 300 ms
Closed Power Terminals to All Other Points ................ Vrms 2,000
Shock, 11 ms 1/2 Sine (peak), operating ......................... G's Peak 30
Vibration, Sinusoidal 80-2000 Hz, peak (EV500-5/EV500-4) ....
PART NUMBER SELECTION
G's 5/10
Operating Ambient Temperature Range ............................ o
C -40 to +85 Sample Part No. EV500 4 A
Load Life (mechanical/electrical) 1...................................... Auxiliary Contacts
cycles See Page 21 4 = without
Operate Time, 25oC .............................................................. 5 = with
Close (includes bounce) Typ. ...................................... ms 40 Coil Voltage
Bounce (after close only), Max. .................................. A = 12 Vdc
ms 5 B = 24 Vdc
Release Time (includes arcing), Max. at 2500 A ....... ms 20
Insulation Resistance @ 500 Vdc, Min. ............................ Mohm 100 Refer to EV500 Sales Drawing for complete
Weight, Nominal .................................................................. pound (kg) 3.38 (1.53) specifications.
1. See EV500 sales drawing for complete specifications, including normal capacitive pre-charge, make plus abnormal make and break ratings.
2. Current Carry: 750 A @ 25oC. Derate 2.5 A/oC to 600A @ 85oC for still air, no heat sink. Reference National Electric Code for specific
conductor size recommendation versus current. For >600A carry, call factory and request the "EV500" Current Carry study" for additional data.
Tyco Electronics / www.tycoelectronics.com / Factory Direct Technical Support: 800-253-4560, ext. 2023 (U.S., Canada, Mexico) or 805-220-2020, ext. 2023 (International) 20
EV500 Contact Ratings
Features:
C UR RE NT vs T IM E
C ON TA CT S C LOSED I NT O 7 0 % AN D 9 0% C A PAC IT OR PR E C HA R GE
7 50
7 00
6 50
6 00
5 50
5 00
4 50
4 00
3 50
3 00
Features:
2 50
2 00
1 50
1 00
50
0
0 1 2 3 4 5 6 7 8
L IF E R A T IN G S A N D Q U A L IF IC A T IO N T E S T P L A N
N o rm a l O p e ra tio n s A b n o rm a l O p e ra tio n s
Test # 1 2 3 4
C u rre n t re fe re n c e g ra p h a n d -2 5 0 A 2500 A
V o lta g e te s t circ u it d ia g ra m (s h t. 8 ) 320 V 320 V
Load Type C a p a c itive C a p a c itive R e s istiv e R e s istiv e
% P re C h a rg e 90% 70% N /A N /A
S w itc h M o d e m ake m ake m a k e / b re a k b re a k o n ly
o n ly o n ly
S equence
1 1 0 K c y c le s 1 0 c yc le s 2 2
2 10K 10 2
3 10K 10 2
4 10K 10 2 2
5 10K 10 2
E tc . C o n tin u e C y c lin g to R e la y F a ilu re
T h e te s tin g o b je c tiv e is to v e rify p ro p e r re la y fu n c tio n fo r a g ive n n u m b e r o f c o n se c u tiv e a n d cu m u la tiv e
c yc le s u n d e r b o th n o rm a l a n d a b n o rm a l co n d itio n s in a v a rie ty o f lo a d s w itc h in g a p p lic a tio n s . T h e life
ra tin g o f 4 0 K cy c le s m in im u m w a s c a lc u la te d w ith 9 5 % W e ib u ll re lia b ility .
21 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
EV200 Series Contactor With 1 Form A (SPST-NO)
Contacts Rated 500+ Amps, 12-900VDC
Product Facts
■ 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).
■ Built-in coil economizer – only
1.7W hold power @ 12VDC and it
limits back EMF to 0V. Models
requiring extenal economizer also
available.
■ Optional auxiliary contact for easy
monitoring of power contact
position.
■ Hermetically sealed – intrinsically
safe, operates in explosive/harsh
environments with no oxidation or
contamination of coils or contacts,
including long periods of non-
operation.
■ Versatile coil/power connections. Typical EV200 applications include battery
EV200 Series Contactor
■ CE marked for EC applications. (CZONKA® Relay, Type III) switching and back-up, DC voltage power
■ AIAG QS9000 designed, built and control, circuit protection and safety.
File E208033 For factory-direct application assistance, dial
approved
800-253-4560, ext. 2053, or 805-220-2053.
Performance Data
Parameter Units Value for EV200 Series Coil Operating Voltage (valid over temperature range)
Contact Arrangement, power contacts 1 Form A (SPST-NO) Voltage (will operate) 9-36VDC 32-95VDC 48-95VDC
Rated Operating Voltage VDC 12 - 900 Voltage (Max.) 36VDC 95VDC 95VDC
Continuous (Carry) Current, Typical A 500 @ 85°C, 400 mcm conductors Pickup (close) Voltage Max. 9VDC 32VDC 48VDC
Consult Factory for required conductors for higher (500+ A) currents
Hold Voltage (Min.) 7.5VDC 22VDC 34VDC
Make/Break Current at Various Voltages 1/ A See next page
Dropout (open) Voltage (Min.) 6VDC 18VDC 27VDC
Break Current at 320VDC 1/ A 2,000, 1 cycle 3/
Inrush Current (Max.) 3.8A 1.3A 0.7A
Contact Resistance, Typ. (@200A) mohms 0.2
Holding Current (Avg.) 0.13A@12V, 0.07A@24V 0.03A@48V 0.02A@72V
Load Life Cycles See next page
Inrush Time (Max.) 130ms 130ms 130ms
Mechanical Life Cycles 1 million
Contact Arrangement, auxiliary contacts 1 Form A (SPST-NO)
Aux. Contact Current, Max. A 2A @ 30VDC / 3A @ 125VAC
Aux. Contact Current, Min. mA 100mA @ 8V Part Numbering System
Aux. Contact Resistance, Max. ohms 0.417@ 30VDC / .150 @ 125VAC
Operate Time @ 25°C Typical Part Number EV200 A A A N A
Close (includes bounce), Typ. ms 15 Series:
Bounce (after close only), Max. ms 7 EV200 = 500+ Amp, 12-900VDC Contactor
Release (includes arcing), Max @ 2000A ms 12 Contact Form:
Dielectric Withstanding Voltage Vrms 2,200 @ sea level (leakage <1mA) A = Normally Open H = Normally Open with Aux. Contacts
Insulation Resistance @ 500VDC megohms 100 2/ Coil Voltage:
Shock, 11ms 1/2 sine, peak, operating G 20 A = 9-36VDC (1 = requires external coil economizer)
D = 32-95VDC (2 = requires external coil economizer)
Vibration, sine, 80-2000Hz., peak G 20 J = 48-95VDC (3 = requires external coil economizer)
Operating Ambient Temperature °C -40 to +85 Coil Wire Length:
Weight, Nominal lb.(kg) .95 (.43) A = 15.3 in (390 mm) B = 6.0 in (152 mm)
Coil Terminal Connector:
1/
Main power contacts N = None
2/
50 at end of life B = Yazaki 7282-5558-10 male, 7114-4102-02, 7158-3030-50
3/
Does not meet dielectric & IR after test, 1700 amp for unit with Aux. Contacts +red is pin 2 (B length only)
C = Molex Mini-fit Jr, 2 Ckt, Female 18-24, P/N 39-01-2020 &
39-00-0060 +red is pin 1 (A length only)
Mounting & Power Terminals:
A = Bottom Mount & Male 10mm x M8 Terminals
© 2004 by Tyco Electronics Corporation. All Rights Reserved.
KILOVAC, CZONKA and TYCO are trademarks.
Other products and company names mentioned herein may be trademarks of their
respective owners.
1
Catalog EV200-TBD Dimensions are in inches and Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 7-04 millimeters unless otherwise reference purposes only. Canada: 1-905-470-4425 Hong Kong: 852-2735-1628
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Japan: 81-44-844-8013
www.tycoelectronics.com are metric equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-141-810-8967
500+ Amp, 12-900VDC Contactor with
1 Form A (SPST-NO) Contacts
Outline Dimensions
1.05 ± .01 M8 x 1.25 POWER TERMINALS
2.29 ± .02 DIA
(26.67 ± .26) (HARDWARE SUPPLIED):
(58.19 ± .51) 2 X M8 WASHER, STAINLESS
2 X M8 LOCKWASHER – SPLIT RING, STAINLESS
2 X M8 x 1.25 NUT, STAINLESS
A1 "+" POSITIVE TERMINAL TORQUE 80 TO 100 IN-LB (8.8 TO 11 NM)
1.65 ± .01
(42.0 ± .26)
2.688 ± .01
(68.28 ± .26)
WHITE = AUXILIARY CONTACT
AUXILIARY CONTACT LEADS (WHEN ORDERED)
BLACK = – COIL
RED = + COIL
COIL LEADS
SEE COIL WIRE
LENGTH IN P/N
.55 ± .025
(14.04 ± .63)
Estimated Make & Break Power Switching Ratings Electrical Load Life Ratings for Typical EV Applications
Continuous Current Carry Region 200A Non-continuous Current Carry Region Make/Break Life Capacitive & Resistive Loads at 320VDC (1) (2)
100,000
@90% capacitive pre-charge (make only) see chart below Cycles 50,000
@80% capacitive pre-charge (make only) see chart below Cycles 50
10,000 @200A make/break (2 consecutive, reverse polarity) (1) Cycles 12
600
28 VDC
180
270
VD
1,000
900
(1) Resistive load includes inductance L = 25µH. Load @ 2500A tested @ 200µH.
400
VDC
120
100
EV200 Capacitive Make Test Curves for Pre-Charged Motor Controller
700
650
10
600
550 80% Minimum
Pre Charge
1 500
1 10 100 1,000 10,000
Load Current (A) 450
NOTES: 90% Nominal
Current (A)
400
1) For resistive loads with 300µH maximum inductance Pre Charge
2) Estimates based on extrapolated data. User is encouraged to verify rating in actual application. 350
3) End of life when dielectric strength between terminals falls below 50 megohms @ 500VDC. 300
4) The maximum contact make and break power is estimated at 208KW.
Break only above 208KW to avoid contact welding. 250
200
150
100
50
0
0.0 0.5 1.0 1.5 2.0
Time (ms)
0V
40 dc
V
0V R eg i o n o f
Bi-directional power switching
dc
dc C on t a c t
L ife C y c le s
L e v it a ti on .
1 ,0 0 0
O pe r at io n Fast operate and release time
6
P ro h ib i te d
0
0
27
V
dc
0V
18
dc
90
00
1 0 0
0V
Vd
dc
c
1 0
1
1 1 0 1 0 0 1 ,0 0 0 1 0 ,0 0 0 1 0 0 ,0 0 0
S w itc hin g C u r re n t
* 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.
PRODUCT SPECIFICATIONS COIL DATA***
Part Number UNIT EV250-1A EV250-1B Parameter EV250-1A EV250-1B Units
Contact Arrangement .......................................................... SPST-NO SPST-NO Voltage* (nominal ) 12 24 Vdc
Contact Form ........................................................................ X X Pickup (close), max. 8.3 16.6
Continuous Current Carry, Max. ........................................ Continuous Hold, max/min ** 5.1/3.8
A 400 400 10.2/7.6
6.5 Minutes .................................................................... A 500 500 Dropout (open), min. 0.88 - 3.3 2.4 - 6.6
Break Current @ 320 Vdc ................................................... A 2,500 2,500 Coil Resistance
Contact Resistance, Max. ................................................... ohms 0.0003 0.0003
@ 25oC, +/- 10% 3 12 Ohms
Contact Resistance, Typ. .................................................... ohms 0.0001 - 0.0002 0.0001 - 0.0002
Coil Energy, max. 0.2 0.2 J
Dielectric at Sea Level (leakage < 1mA) ............................ Vrms 2,200 2,200
Shock, 11 ms 1/2 Sine (peak), operating ......................... Coil Clamping 3 x nom. 3 x nom.
G's Peak 30 30 * Do not apply continously. Requires external coil economizer. Other special coil
Vibration, Sinusoidal (80-2000 Hz, peak) ......................... G's 20 20 voltages available upon request.
Tyco Electronics / www.tycoelectronics.com / Factory Direct Technical Support: 800-253-4560, ext. 2023 (U.S., Canada, Mexico) or 805-220-2020, ext. 2023 (International) 16
EV250 Contact Ratings
Features:
C UR RE NT vs T IM E
C ON TA CT S C LOSED I NT O 7 0 % AN D 9 0% C A PAC IT OR PR E C HA R GE
7 50
7 00
6 50
6 00
5 50
5 00
4 50
4 00
3 50
3 00
2 50
2 00 Features:
1 50
1 00
50
0
0 1 2 3 4 5 6 7 8
L IF E R A T IN G S A N D Q U A L IF IC A T IO N T E S T P L A N
N o rm a l O p e ra tio n s A b n o rm a l O p e ra tio n s
Test # 1 2 3 4
C u rre n t re fe re n c e g ra p h a n d -2 5 0 A 2500 A
V o lta g e te s t circ u it d ia g ra m (s h t. 8 ) 320 V 320 V
Load Type C a p a c itive C a p a c itive R e s istiv e R e s istiv e
% P re C h a rg e 90% 70% N /A N /A
S w itc h M o d e m ake m ake m a k e / b re a k b re a k o n ly
o n ly o n ly
S equence
1 1 0 K c y c le s 1 0 c yc le s 2 2
2 10K 10 2
3 10K 10 2
4 10K 10 2 2
5 10K 10 2
E tc . C o n tin u e C y c lin g to R e la y F a ilu re
T h e te s tin g o b je c tiv e is to v e rify p ro p e r re la y fu n c tio n fo r a g ive n n u m b e r o f c o n se c u tiv e a n d cu m u la tiv e
c yc le s u n d e r b o th n o rm a l a n d a b n o rm a l co n d itio n s in a v a rie ty o f lo a d s w itc h in g a p p lic a tio n s . T h e life
ra tin g o f 4 0 K cy c le s m in im u m w a s c a lc u la te d w ith 9 5 % W e ib u ll re lia b ility .
(1) Resistive load includes inductance L = 25 uH. Load @ 2500 A tested @ 200 uH.
(2) Conductor: 2 each of Copper 54 mm2 (AWG 0) required for > 250 A carry.
1 Copper (AWG 0) conductor recommneded for ≤ 250 A
(3) Life based on projected Weibull Life with 95% Reliability
19 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
28-1800 Vdc
Features:
Kilovac EV250-2A & 2B - 400 Amps ("Czonka II EVX")
Make & Break Load Switching Hydrogen dielectric for power switching high
current loads
400 A carry, 2,500 A interrupt @ 320 Vdc
Ideal for circuit protection, control, battery
switching, and main power safety disconnect
Versatile power, voltage, and current
operating range: 28-1800Vdc tested
Internal coil economizer provides:
− 4W typical hold power independent
of temperature & voltage range
− EMI spectrum tested and approved
− Built-in coil suppression
Patented "hammer effect" mechanism breaks
light contact welds
Patented hermetically "Super-sealed"
environment chamber uniquely protects ALL
Note: Dimensions in inches. Multiply values by 25.4 for dimensions in mm. moving parts
Features:
Can operate in harsh environments
CONTACT RATINGS* Moving contact rotates to provide fresh
contact surface for low contact resistance
1 0 0 ,0 0 0
400A 9 0 0 0A and low power comsumption
M o m en t a ry C a rry
R eg i o n
Sealed control connector. Mating connector
with flying leads P/N 2005 available, see
1 0 ,0 0 0 page 59
12
0V Special versions available:
28
40
− Economical (-8A/B) for light duty
dc
V
0V R eg i o n o f
dc
dc C on t a c t
L e v it a ti on .
power switching (without arc blowout
L ife C y c le s
1 ,0 0 0
O pe r at io n
magnets
6
P ro h ib i te d
0
0
27
V
0V
c
18
dc
90
00
1 0 0
0V
Vd
dc
c
1 0
1
1 1 0 1 0 0 1 ,0 0 0 1 0 ,0 0 0 1 0 0 ,0 0 0
17 Tyco Electronics / www.tycoelectronics.com / Factory Direct Technical Support: 800-253-4560, ext. 2023 (U.S., Canada, Mexico) or 805-220-2020, ext. 2023 (International)
EV250 Contact Ratings
Features:
C UR RE NT vs T IM E
C ON TA CT S C LOSED I NT O 7 0 % AN D 9 0% C A PAC IT OR PR E C HA R GE
7 50
7 00
6 50
6 00
5 50
5 00
4 50
4 00
3 50
3 00
2 50
2 00 Features:
1 50
1 00
50
0
0 1 2 3 4 5 6 7 8
L IF E R A T IN G S A N D Q U A L IF IC A T IO N T E S T P L A N
N o rm a l O p e ra tio n s A b n o rm a l O p e ra tio n s
Test # 1 2 3 4
C u rre n t re fe re n c e g ra p h a n d -2 5 0 A 2500 A
V o lta g e te s t circ u it d ia g ra m (s h t. 8 ) 320 V 320 V
Load Type C a p a c itive C a p a c itive R e s istiv e R e s istiv e
% P re C h a rg e 90% 70% N /A N /A
S w itc h M o d e m ake m ake m a k e / b re a k b re a k o n ly
o n ly o n ly
S equence
1 1 0 K c y c le s 1 0 c yc le s 2 2
2 10K 10 2
3 10K 10 2
4 10K 10 2 2
5 10K 10 2
E tc . C o n tin u e C y c lin g to R e la y F a ilu re
T h e te s tin g o b je c tiv e is to v e rify p ro p e r re la y fu n c tio n fo r a g ive n n u m b e r o f c o n se c u tiv e a n d cu m u la tiv e
c yc le s u n d e r b o th n o rm a l a n d a b n o rm a l co n d itio n s in a v a rie ty o f lo a d s w itc h in g a p p lic a tio n s . T h e life
ra tin g o f 4 0 K cy c le s m in im u m w a s c a lc u la te d w ith 9 5 % W e ib u ll re lia b ility .
(1) Resistive load includes inductance L = 25 uH. Load @ 2500 A tested @ 200 uH.
(2) Conductor: 2 each of Copper 54 mm2 (AWG 0) required for > 250 A carry.
1 Copper (AWG 0) conductor recommneded for ≤ 250 A
(3) Life based on projected Weibull Life with 95% Reliability
19 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
28-1800 Vdc
Kilovac EV250-5A - 400 Amps ("Czonka II EVX") Features:
Make & Break Load Switching 400 A carry, 2,500 A interrupt @ 320 Vdc
Hydrogen dielectric for power switching high
current loads
Internal Hall Effect contact position sensor
detects contact welds
Ideal for circuit protection, control, battery
switching, and main power safety disconnect
Versatile power, voltage, and current
operating range: 28-1800Vdc switch tested
Internal economizer provides:
− 4W typical hold power independent
of temperature & voltage variance
− EMI spectrum tested and approved
Patented "hammer effect"
mechanism breaks light contact welds
Patented hermetically "Super-sealed"
environment chamber uniquely protects ALL
Features:
moving parts
CONTACT RATINGS* Can operate in harsh environments
Moving contact rotates to provide fresh
1 0 0 ,0 0 0
400A 9 0 0 0A contact surface for low contact resistance
M o m en t a ry C a rry and low power consumption
R eg io n
Sealed control connector. Mating connector
1 0 ,0 0 0 with flying leads P/N 2625 available, see
12
0V page 59
28
40 dc
Bi-directional power switching
V
0V R eg io n o f
dc
dc C on t a c t
Fast operate and release time
L ife C y c le s
1 ,0 0 0
L e v it a tion .
O pe r at io n
Low power consumption
60
P ro h ib ite d
0
27
V
Auxiliary contacts
dc
0V
18
dc
90
00
1 0 0
0V
Vd
dc
c
1 0
1
1
Ω
ΩΩ
Ω
1 0
Ω
1 0 0 1 ,0 0 0 1 0 ,0 0 0 1 0 0 ,0 0 0
Ω ΩΩΩ
Ω
Ω
Ω
Ω
Ω
Ω Ω S w itc h i n g C u r re n t Ω
ΩΩ
Ω
Ω
Ω
ΩΩ
Ω Ω Ω
Ω
ΩΩ
Ω
Ωthe
* For circuit conditions and actual data Ω
refer to EV250 Hot Switch study. Since each application is unique, user is encouraged to verify rating
in actual application.
* Refer to sales drawing, qualification test plan for actual mix of pre-charge and break currents used on each cycle.
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 18
EV250 Contact Ratings
Features:
C UR RE NT vs T IM E
C ON TA CT S C LOSED I NT O 7 0 % AN D 9 0% C A PAC IT OR PR E C HA R GE
7 50
7 00
6 50
6 00
5 50
5 00
4 50
4 00
3 50
3 00
2 50
2 00 Features:
1 50
1 00
50
0
0 1 2 3 4 5 6 7 8
L IF E R A T IN G S A N D Q U A L IF IC A T IO N T E S T P L A N
N o rm a l O p e ra tio n s A b n o rm a l O p e ra tio n s
Test # 1 2 3 4
C u rre n t re fe re n c e g ra p h a n d -2 5 0 A 2500 A
V o lta g e te s t circ u it d ia g ra m (s h t. 8 ) 320 V 320 V
Load Type C a p a c itive C a p a c itive R e s istiv e R e s istiv e
% P re C h a rg e 90% 70% N /A N /A
S w itc h M o d e m ake m ake m a k e / b re a k b re a k o n ly
o n ly o n ly
S equence
1 1 0 K c y c le s 1 0 c yc le s 2 2
2 10K 10 2
3 10K 10 2
4 10K 10 2 2
5 10K 10 2
E tc . C o n tin u e C y c lin g to R e la y F a ilu re
T h e te s tin g o b je c tiv e is to v e rify p ro p e r re la y fu n c tio n fo r a g ive n n u m b e r o f c o n se c u tiv e a n d cu m u la tiv e
c yc le s u n d e r b o th n o rm a l a n d a b n o rm a l co n d itio n s in a v a rie ty o f lo a d s w itc h in g a p p lic a tio n s . T h e life
ra tin g o f 4 0 K cy c le s m in im u m w a s c a lc u la te d w ith 9 5 % W e ib u ll re lia b ility .
(1) Resistive load includes inductance L = 25 uH. Load @ 2500 A tested @ 200 uH.
(2) Conductor: 2 each of Copper 54 mm2 (AWG 0) required for > 250 A carry.
1 Copper (AWG 0) conductor recommneded for ≤ 250 A
(3) Life based on projected Weibull Life with 95% Reliability
19 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
28-1800 Vdc
Kilovac PD90X 90 Amps ("Spud") Make & Break Load Switching Features:
Vacuum dielectric for power switching
90 A carry, 350 A overload @ 320 Vdc
Versatile power, voltage, and current
operating range
Ideal for circuit protection and control
Bi-directional switching
Fast operate and release time
Low power consumption
Vacuum-sealed contacts; can operate in
harsh environments
Meets many requirements of SAE ARD50031
Optimized for power switching
Features:
CONTACT RATINGS*
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 14
CAP200 Series Contactor With 1 Form A (SPST-NO)
Contacts Rated up to 500 Amps, 12-900VDC
Product Facts
■ Designed to be the smallest,
lightest weight, lowest cost
sealed contactor in the industry
with its current rating.
■ Built-in coil economizer – only
1.7W hold power @ 12VDC and
it limits back EMF to 0V.
(models requiring extenal
economizer also available).
■ Optional auxiliary contact for
easy monitoring of power
contact postion.
■ Hermetically sealed –
intrinsically safe, operates in
explosive/harsh environments
with no oxidation or
contamination of coils or
contacts, including long periods
of non-operation.
■ Versatile coil and power
connections.
■ UL Recognized for the U.S. and
Canada (File E208033).
■ CE marked for EC applications.
■ AIAG QS9000 designed, built For factory-direct application assistance, dial
and approved 800-253-4560, ext. 2053, or 805-220-2053.
Performance Data
Parameter Units Value for CAP200 Series Coil Operating Voltage (valid over temperature range)
Contact Arrangement, power contacts 1 Form A (SPST-NO) Voltage (will operate) 9-36VDC 32-95VDC 48-95VDC
Rated Operating Voltage VDC 12 - 900 Voltage (Max.) 36VDC 95VDC 95VDC
Continuous (Carry) Current, Typical A 500 @ 85°C, 400 mcm conductors Pickup (close) Voltage Max. 9VDC 32VDC 48VDC
Consult Factory for required conductors for higher currents
Hold Voltage (Min.) 7.5VDC 22VDC 34VDC
Make/Break Current at Various Voltages 1/ A See next page
Dropout (open) Voltage (Min.) 6VDC 18VDC 27VDC
Break Current at 320VDC 1/ A 2,000, 1 cycle 3/
Inrush Current (Max.) 3.8A 1.3A 0.7A
Contact Resistance, Typ. (@200A) mohms 0.2
Holding Current (Avg.) 0.13A@12V, 0.07A@24V 0.03A@48V 0.02A@72V
Load Life Cycles See next page
Inrush Time (Max.) 130ms 130ms 130ms
Mechanical Life Cycles 1 million
Contact Arrangement, auxiliary contacts 1 Form A (SPST-NO)
Aux. Contact Current, Max. A 2A @ 30VDC / 3A @ 125VAC
Aux. Contact Current, Min. mA 100mA @ 8V
Aux. Contact Resistance, Max. ohms 0.417@ 30VDC / .150 @ 125VAC Part Numbering System
Dielectric Withstanding Voltage Vrms 2,200 @ sea level
Insulation Resistance @ 500VDC megohms 100 2/ Typical Part Number CAP200 A A A N A
Shock, 11ms 1/2 sine, peak, operating G 20 Series:
CAP200 = 500 Amp, 12-900VDC Contactor
Vibration, sine, 80-2000Hz., peak G 20
Contact Form:
Operating Temperature °C -40 to +85 A = Normally Open H = Normally Open with Aux. Contacts
Weight, Nominal lb.(kg) .95 (.43) Coil Voltage:
A = 9-36VDC (1 = requires external coil economizer)
1/
Main power contacts D = 32-95VDC (2 = requires external coil economizer)
2/
50 at end of life J = 48-95VDC (3 = requires external coil economizer)
3/
Does not meet dielectric & IR after test, 1700 amp for unit with Aux. Contacts Coil Wire Length:
4/
Use with AMP LOUVERTAC 5-192013-9. Consult factory for threaded mount socket. A = 15.3 in (390 mm) B = 6.0 in (152 mm)
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.
© 2004 by Tyco Electronics Corporation. All Rights Reserved. X = Special configuration (consult factory)
KILOVAC, AMP, LOUVERTAC and TYCO are trademarks. Mounting & Power Terminals:
Other products and company names mentioned herein may be trademarks of their A = Bottom Mount & Male 10mm x 8 Terminals C = Plug-in Terminals 4/
respective owners.
1
Catalog 1654770 Dimensions are in inches and Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 6-04 millimeters unless otherwise reference purposes only. Canada: 1-905-470-4425 Hong Kong: 852-2735-1628
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Japan: 81-44-844-8013
www.tycoelectronics.com are metric equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-141-810-8967
500 Amp, 12-900VDC Contactor with
1 Form A (SPST-NO) Contacts
Outline Dimensions
1.05 ± .01 M8 x 1.25 POWER TERMINALS
2.29 ± .02 DIA
(26.67 ± .26) (HARDWARE SUPPLIED):
(58.19 ± .51) 2 X M8 WASHER, STAINLESS
2 X M8 LOCKWASHER – SPLIT RING, STAINLESS
2 X M8 x 1.25 NUT, STAINLESS
A1 "+" POSITIVE TERMINAL TORQUE 80 TO 100 IN-LB (8.8 TO 11 NM)
1.65 ± .01
(42.0 ± .26)
2.688 ± .01
(68.28 ± .26)
WHITE = AUXILIARY CONTACT
AUXILIARY CONTACT LEADS (WHEN ORDERED)
BLACK = – COIL
RED = + COIL
COIL LEADS
SEE COIL WIRE
LENGTH IN P/N
.55 ± .025
(14.04 ± .63)
Estimated Make & Break Power Switching Ratings Electrical Load Life Ratings for Typical Applications
Continuous Current Carry Region 200A Non-continuous Current Carry Region Make/Break Life Capacitive & Resistive Loads at 320VDC (1) (2)
100,000
@90% capacitive pre-charge (make only) see chart below Cycles 50,000
@80% capacitive pre-charge (make only) see chart below Cycles 50
10,000 @200A make/break (2 consecutive, reverse polarity) (1) Cycles 12
600
28 VDC
180
270
VDC
0V
VD
DC
1,000 (1) Resistive load includes inductance L = 25µH. Load @ 2500A tested @ 200µH.
900
120
VDC
C
100
CAP200 CAPACITIVE MAKE TEST CURVES
700
650
10 600
Amps
Product Facts
Designed to be the lowest cost
sealed contactor in the industry
with its current rating (500+A carry,
2000A interrupt at 320Vdc).
Available with bottom or side
mounting -- not position senstive.
Optional auxiliary contact for easy
monitoring of power contact
position.
Hermetically sealed – intrinsically
safe, operates in explosive/harsh
environments with no oxidation or
contamination of coils or contacts,
including long periods of non-
operation.
Typical applications include battery
switching and backup, DC voltage
power control, circuit protection
and safety.
Versatile coil/power connections.
Designed and built in accordance
to AIAG QS9000.
For factory-direct application assistance, contact Earle Alldredge, product manager.
Dial 800-253-4560, ext. 2055, or 805-220-2055. Email earle.alldredge@tycoelectronics.com
Performance Data
Parameter Units Value for LEV200 Series Coil Data (valid over temperature range) 4/
Contact Arrangement, power contacts 1 Form X (SPST-NO-DM) Nominal Voltage 12Vdc 24Vdc 48Vdc
Rated Operating Voltage Vdc 12 - 900 Pickup Voltage (will operate) 9.0Vdc 19.0Vdc 38.0Vdc
Continuous (Carry) Current, Typical A 500 @ 65°C, 400 mcm conductors Voltage (Max.) 15Vdc 30Vdc 60Vdc
Consult Factory for required conductors for higher (500+ A) currents
Dropout Voltage 0.75 - 2.0Vdc 1.0 - 5.0Vdc 2.0 - 7.0Vdc
Make/Break Current at Various Voltages 1/ A See next page
Coil Resistance @ 25° (Typ.) 11 ohms 40 ohms 145 ohms
Break Current at 320Vdc 1/ A 2,000, 1 cycle 3/
Contact Resistance, Typ. (@200A) mohms 0.2 Part Numbering System
Load Life Cycles See next page
Typical Part Number LEV200 A 4 N A A
Mechanical Life Cycles 100,000
Series:
Contact Arrangement, auxiliary contacts 1 Form A (SPST-NO) LEV200 = 500+ Amp, 12-900Vdc Contactor
Aux. Contact Current, Max. A 2A @ 30Vdc / 3A @ 125Vac Contact Form:
Aux. Contact Current, Min. mA 100mA @ 8V A = Normally Open
Aux. Contact Resistance, Max. ohms 0.417@ 30Vdc / .150 @ 125Vaac H = Normally Open with Aux. Contacts. (Option “H” requires
Operate Time @ 25°C option “A” in Coil Wire Length and option “N” in Coil
Close (includes bounce), Typ. ms 25 Terminal Connector.)
Bounce (after close only), Max. ms 7 Note: Other auxiliary contact forms available. Consult factory.
Release (includes arcing), Max @ 2000A ms 12 Coil Voltage:
Dielectric Withstanding Voltage Vrms 2,200 @ sea level (leakage <1mA) 4 = 12Vdc 5 = 24Vdc 6 = 48Vdc 7 = 72Vdc
8 = 96Vdc L = 110Vdc O = 115Vac 9 = 240Vac
Insulation Resistance @ 500Vdc megohms 100 2/ Notes: Consult factory for detailed specifications and availability of
Shock, 11ms 1/2 sine, peak, operating G 20 coils not listed in “Coil Data” table above.
Vibration, sine, 80-2000Hz., peak G 20 In coil voltage codes, 115Vac is designated by the letter “O”
rather than the numeral “0.”
Operating Ambient Temperature °C -40 to +85
Coil Wire Length:
Weight, Typical lb.(kg) 1.3 (.60) A = 15.3 in (390 mm) N = None (Requires option “A” in next step.)
1/
Coil Terminal Connector:
Main power contacts N = None, stripped wires (Requires option “A” in previous step.)
2/
50 at end of life A = Studs, #10-32 Threaded (Electrical connection is made to the tab
3/
Does not meet dielectric & IR after test, 1700 amp for unit with Aux. Contacts at the base of the stud.)
4/
Contacts will operate with 0.8Vnom < Vcoil < 1.1Vnom over temperture range. Note: Specify option A, stripped wires, for coil voltages > 96Vdc
Mounting & Power Terminals:
A = Bottom Mount & Male 10mm x M8 Threaded Terminals
F = Side Mount & Male 10mm x M8 Threaded Terminals
© 2007 by Tyco Electronics Corporation. All Rights Reserved. Consult factory regarding other available mountings and power terminals.
KILOVAC, TE Logo and Tyco Electronics are trademarks.
Other products and company names mentioned herein may be trademarks of their
respective owners.
1
Catalog 9-1773439-1 Dimensions are in inches and Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Revised 8-07 millimeters unless otherwise reference purposes only. Canada: 1-905-470-4425 Hong Kong: 852-2735-1628
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Japan: 81-44-844-8013
www.tycoelectronics.com are metric equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-141-810-8967
500+ Amp, 12-900VDC Contactor with
1 Form X (SPST-NO-DM) Contacts
Outline Dimensions
Estimated Make & Break Power Switching Ratings Electrical Load Life Ratings for Typical LEV Applications
Make and Break Power Switching Region 650A Break Only Above 650A Make/Break Life Capacitive & Resistive Loads at 320VDC (1) (2)
100,000
@90% capacitive pre-charge (make only) see chart below Cycles 50,000
@80% capacitive pre-charge (make only) see chart below Cycles 50
10,000 2,000A (break only) (1) Cycles 1*
600
28 VDC
180
VD
DC
Estimated Life (Cycles)
1,000
900
(1) Resistive load includes inductance L = 25μH. Load @ 2500A tested @ 200μH.
(2) Life based on projected Weibull Life with 95% teliability.
400
VDC
120
DCV
C
100 LEV200 Capacitive Make Test Curves for Pre-Charged Motor Controller
700
650
10 600
550 80% Minimum
500 Pre Charge
1 450
1 10 100 1,000 10,000
Load Current (A) 400
Current (A)
90% Nominal
NOTES: 350 Pre Charge
1) For resistive loads with 300H maximum inductance. Consult factory for inductive loads.
300
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. 250
4) The maximum make current is 650A to avoid contact welding.
200
150
100
50
0
0.0 0.5 1.0 1.5 2.0
Time (ms)
Product Facts
■ Designed to be the smallest,
lightest weight, lowest cost
sealed contactor in the industry
with its current rating.
■ Built-in coil economizer
(models requiring external
economizer also available).
■ Optional auxiliary contact for
easy monitoring of power
contact position.
■ Hermetically sealed –
intrinsically safe, operates in
explosive/harsh environments
with no oxidation or
contamination of coils or
contacts, including long periods
of non-operation.
■ Versatile coil and power
connections.
■ MIL-PRF-32085 versions in
development
For factory-direct application assistance, dial
800-253-4560, ext. 2053, or 805-220-2053.
Performance Data
Parameter Units Value for MAP200 Series Coil Operating Voltage (valid over temperature range)
Contact Arrangement, power contacts 1 Form A (SPST-NO) Voltage (will operate) 18-32VDC
Rated Operating Voltage VDC 12 - 900 Voltage (Max.) 32VDC
Continuous (Carry) Current, Typical A 500 @ 85°C, 400 mcm conductors Pickup (close) Voltage Max. 18VDC
Consult Factory for required conductors for higher currents
Hold Voltage (Min.) 10VDC
Make/Break Current at Various Voltages 1/ A See next page
Dropout (open) Voltage (Min.) 2VDC
Break Current at 320VDC 1/ A 2,000, 1 cycle
Inrush Current (Max.) 4.5A
Contact Resistance, Typ. (@200A) mohms 0.2
Holding Current (Avg.) 0.5A
Load Life Cycles See next page
Inrush Time (Max.) 100ms
Mechanical Life Cycles 1 million
Contact Arrangement, auxiliary contacts 1 Form A (SPST-NO)
Aux. Contact Current, Max. A 2A @ 30VDC / 3A @ 125VAC
Aux. Contact Current, Min. mA 100mA @ 8V Part Numbering System
Aux. Contact Resistance, Max. ohms 0.417@ 30VDC / .150 @ 125VAC
Typical Part Number MAP200 A R D E A
Dielectric Withstanding Voltage Vrms 2,200 @ sea level
Series:
Insulation Resistance @ 500VDC megohms 100 2/ MAP200 = 500 Amp, 12-900VDC Contactor
Shock, 11ms 1/2 sine, peak, operating G 20 Contact Form:
Vibration, sine, 80-2000Hz., peak G 20 A = Normally Open H = Normally Open with Aux. Contacts
Operating Temperature °C -55 to +85 Coil Voltage:
Weight, Nominal lb.(kg) .95 (.43) R = 18-32VDC
Coil Wire Length:
1/ Main power contacts A = 15.3 in (390 mm)
2/ 50 at end of life B = 6.0 in (152 mm)
3/ Use with AMP LOUVERTAC 5-192013-9. Consult factory for threaded mount D = Coil connector on relay (requires option “E” or “X” in next step).
socket. Coil Terminal Connector:
N = No connector
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)
Mounting & Power Terminals:
A = Bottom Mount & Male M8 x 1.25 Thread Terminals
B = Bottom Mount & Female 1/4-20 Thread Terminals
© 2004 by Tyco Electronics Corporation. All Rights Reserved. C = Bottom Mount & Plug-in Terminals 3/
KILOVAC, AMP, LOUVERTAC and TYCO are trademarks. D = Bottom Mount & Female M6 x 1 Thread Terminals
Other products and company names mentioned herein may be trademarks of their
respective owners.
1
Catalog 1654857 Dimensions are in inches and Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Issued 6-04 millimeters unless otherwise reference purposes only. Canada: 1-905-470-4425 Hong Kong: 852-2735-1628
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Japan: 81-44-844-8013
www.tycoelectronics.com are metric equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-141-810-8967
500 Amp, 12-900VDC Contactor with
1 Form A (SPST-NO) Contacts
Outline Dimensions
2.688 ± .01
(68.28 ± .26)
1.05 ± .01
LABEL (26.67 ± .26)
2 X M6 x 1 THREAD
.45 (11.43) MIN DEPTH (11 THREADS)
TORQUE VS THREAD ENGAGEMENT
.800 ± .01 8 TO 11 THREADS: 80 TO 100 IN-LB (9.1 TO 11.3 NM)
(20.3 ± .26) 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)
1.65 ± .01
(42.0 ± .26)
2.245 ± .025
(57.02 ± .635) 2.523 ± .025
(64.08 ± .635)
.546 ± .01
(13.87 ± .26)
3.17 ± .01
(80.48 ± .26)
Estimated Make & Break Power Switching Ratings Electrical Load Life Ratings for Typical Applications
Continuous Current Carry Region 200A Non-continuous Current Carry Region Make/Break Life Capacitive & Resistive Loads at 320VDC (1) (2)
100,000
@90% capacitive pre-charge (make only) see chart below Cycles 50,000
@80% capacitive pre-charge (make only) see chart below Cycles 50
10,000 @200A make/break (2 consecutive, reverse polarity) (1) Cycles 12
600
28 VDC
180
270
VDC
0V
VD
DC
1,000 (1) Resistive load includes inductance L = 25µH. Load @ 2500A tested @ 200µH.
900
120
VDC
C
Product Facts
Multi-pole configurations
Normally open, normally
closed and mixed contact
arrangements
Optional quick connect tabs
for sensing
Small, lightweight & cost-
effective – designed to be the
smallest, lowest cost
contactor in the industry with
its current rating
Standard models available
with 12VDC, 24VDC and 115
VAC coils. Consult factory for
240VAC coil models.
1 Form A auxiliary contacts For factory-direct application assistance, dial
File E208033 800-253-4560, ext. 2055, or 805-220-2055.
Product Specifications
Parameter Units 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 Voltage Range V 9.6-13.2 19.2-26.4 92-126.5 19.2-26.4
Max. Contact Voltage (transient) V 750Vrms or 60VDC
Hold Voltage V ≥0.5Vnom ≥0.5Vnom ≥0.5Vnom ≥0.5Vnom
Continuous (Carry) Current Arms or ADC 200/pole (Form X)
150/pole (Form Y) Dropout Voltage V ≤0.1Vnom ≤0.1Vnom ≤0.1Vnom ≤0.2Vnom
Power Switching Form X (0.7-1.0 PF) Cycles 2,000 @ 300Arms
10,000@ 200Arms Coil Resistance Data for Pole Configurations (@25°C)
20,000 @ 100Arms
5,000 @ 200A/48VDC Coil Designator Units A B* C* D*
2 million @ 50A/28VDC Resistance ±10% Ohms X = 36 X = 36 X = 36 Y = 20.8
Power Switching Form Y (0.7-1.0 PF) Cycles 2,000 @ 225Arms XX = 18 XX = 18 XX = 18 YY = 10.4
10,000@ 150Arms XXX = 12 XXX = 12 XXX = 12 YYY = 6.9
20,000 @ 75Arms XY = 13.2 XY = 13.2 XY = 13.2 YXY = 8.1
5,000 @ 150A/48VDC XYX = 9.6 XYX = 9.6 XYX = 9.6
2 million @ 35A/28VDC *Coil resistance not measurable at terminals due to converter/economizer circuit.
Mechanical Life Cycles >2 million
Contact Voltage Drop mV 75 for Form X or Form Y
Coil Current/Power Data for Pole Configurations (@25°C, Vcoil=1.1Vnom)
Auxiliary Contact Arrangement 1 Form A (SPST-NO)
Coil Designator A B**
Auxiliary Contact Rating Arms or ADC 1 @ 30VDC, 3 @ 125VAC
Current/Power X = 0.37 ADC / 4.84W X = 0.33ADC / 3.9W
Dielectric Withstanding Voltage Vrms 2,200 @ sea level XX = 0.73ADC / 9.68W XX = 0.65ADC / 7.6W
Insulation Resistance @ 500VDC Megohms 100 XXX = 1.1ADC / 14.5W XXX = 0.97ADC / 11.3W
Shock, 11ms 1/2 sine, peak G 10 XY = 1.0ADC / 13.2W XY = 0.98ADC / 12.7W
XYX = 1.38ADC / 18.2W XYX = 1.31ADC / 16.5W
Vibration, sine, 10-2000Hz. G 5
Coil Designator C D*** Pick-Up I / Duration
Operating Temperature °C -20 to +60
Current/Power X = 0.067 Arms / 6.8VA Y = 0.13ADC / 3.4W 1.28ADC / 75ms
Storage Temperature °C -40 to +85
XX = 0.115Arms / 11.6VA YY = 0.23ADC / 6.1W 2.4ADC / 75ms
Ambient Humidity %RH 0 to 95 XXX = 0.146Arms / 14.8VA YYY = 0.34ADC / 9.0W 3.0ADC / 75ms
Weight oz. / kg 17.6 - 49.4 / 0.5 -1.4 XY = 0.074Arms / 7.5VA YXY = 0.28ADC / 7.4W 3.0ADC / 75ms
See Outline Dimensions for model-specific weight information. XYX = 0.161Arms / 16.3VA
**Average coil current. ***Economized.
Available Pole Configurations and Applicable Coil Codes
No. of NC Poles (across) 0 1 2 3 Operate/Release Time (25°C, 0.8Vnom ≤ V < Vnom) Typ.
No. of NO Poles (down)
Coil Designator Units A B**** C**** D****
0 Y YY YYY
Coil D Coil D Coil D Operate Time ms 25-50 30-50 50-150 20-30
1 X XY YXY Release Time ms 10-20 70-80 75-100 75-100
Coil A/B/C/E Coil A/B/C/E Coil D
Bounce Time ms 2-5 2-5 2-5 2-5
2 XX XYX
Coil A/B/C/E Coil A/B/C/E ****Includes internal coil suppression.
3 XXX
Coil A/B/C/E © 2003 and 2007 by Tyco Electronics Corporation. All Rights Reserved.
X = Form X (NO-DM) Y = Form Y (NC-DB) FLATMAN, KILOVAC and TE Logo and Tyco Electronics are trademarks.
1
Catalog 1654769 Dimensions are in inches and Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-3611-1514
Issued 11-07 millimeters unless otherwise reference purposes only. Canada: 1-905-470-4425 Hong Kong: 852-2735-1628
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Japan: 81-44-844-8013
www.tycoelectronics.com are metric equivalents. to change. C. America: 52-55-5-729-0425 UK: 44-141-810-8967
200 Amp, 480Vac or 48Vdc Contactor
with 1, 2 or Poles
Outline Dimensions
2.29 .40
(58.2) (10.2)
1.86
OPTIONAL TAB C
(47.2)
TERMINALS
.250 x .032
(6.35 x .813)
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)
A RIGHT ANGLE SCREW
TERMINAL STRIP
ACCEPTS
#24 - #14 WIRE
NUMBER OF POLES
DIM.
1 2 3
1.68 2.67 3.65
A 3.42 2.74
(42.7) (67.7) (92.7)
(86.9) (69.6)
2.14 3.12 4.11
B (54.3) (79.3) (104.4) 3.77 2.98
1.56 2.55 3.53 (95.8) (75.7)
C (39.6) (64.6) (89.7)
17.6 oz. 35.3 oz. 49.4 oz.
WEIGHT (0.5 kg) (1.0 kg) (1.4 kg)
.256 DIA.
(6.5)
B
Features:
CONTACT RATINGS*
15 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
PRE-PRODUCTION
28-1800Vdc
Kilovac PD350X - 500 Amps ("Bubba") Features:
Make & Break Load Switching 500 A carry, 1300 A make overload, 3000 A
break overload, @ 320 Vdc
Hydrogen dielectric for power switching high
current loads
Auxiliary Contacts
Coil Power Economizing - 8 W holding
Versatile power, voltage, and current
operating range
Excellent for safety disconnect and transfer
switch applications
Ideal for circuit protection and control
Bi-directional power switching
Hermetically-sealed contacts; can operate in
harsh environments
Fast operate and release time
Low power consumption
Meets requirements of SAE ARD 50031
Features:
PCB Mount Version shown above is applicable to both PD5 and PD10.
Refer to PD10 for Panel Mount Dimensions.
CONTACT RATINGS*
* 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.
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 12
3.0 kV
Kilovac S02DNA No Load Switching Features:
PC mount form A relay
Vacuum dielectric for low leakage current
applications
100 million cycle mechanical life
2 amp continous carry
Very compact package
Features:
PRODUCT
PRODUCT SPECIFICATIONS
SPECIFICATIONS COIL DATA
Part Number Unit S02DNA Nominal, Volts dc 5 12 24
Contact Arrangment ............................................................ SPST-NO Pickup, Volts dc, Maximum 3.7 9 20
Contact Form ........................................................................ A Drop-Out, Volts dc .5 1.25 3
Voltage Ratings Between Contacts .................................... kV peak 3 Coil Resistance (Ohms ±10%) 140 600 1,000
Current Carry @ DC ............................................................. Amps 2
Contact Resistance .............................................................. Ohms 0.100 PART NUMBER SELEC-
Contact Capacitance ............................................................ pF TION PART NUMBER SELECTION
Between Open Contacts ................................................. pF 1.5
Sample Part No. S02DN A 3 3 5
Closed Contacts to Ground ........................................... pF 6 Contact Form
Operate and Release Time [4] ............................................ ms 1 A = SPST-NO
Coil Voltage
Shock, 11 ms 1/2 Sine (Peak) ............................................ G's 100 1 = 5 Vdc
Vibration ............................................................................... G's Peak 30 2 =12 Vdc
............................................................................................... Hz 10-2,000 3 = 24 Vdc
High Voltage Connections
Temperature Range ............................................................. C
o
3 = Solder Connection
Operating ......................................................................... -20 to +70 Mounting
5 = PC Covered
Storage ............................................................................ -35 to +110
Initial Insulation Resistance ................................................ GigaOhms 10
Mechanical Life .................................................................... Cycles 100 million
Weight, nominal ................................................................... ozz. 0.18
[4] Operation and release times are with external diode suppression, @ 25oC
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 24
10 kV
Kilovac S05LT - PC Mount Version Make & Break Load Switching Features:
Versatile 10kV, 5 amp carry relay
Vacuum dielectric for power switching low
current loads
Widely used in test equipment applications
Flying leads or PC mount available
Very high service life
Kilovac S05LT - Flying Lead Version Make & Break Load Switching Features:
43 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
15 kV
Kilovac S05MTA Make & Break Load Switching Features:
Smallest 15 kV PC mount relay
Vacuum dielectric for power switching low
current loads
SPST normally open contacts
Very high service life
Features:
49 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
1.5 - 2 kV
Kilovac S03BJA335 & S06CBA335 No Load Switching Features:
Small size, high performance relays
Vacuum dielectric for low leakage current
applications
RF ratings to 30 mHz
SPST normally open contacts
Features:
S03BJA335 S06CBA335
23 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
5.0 kV
Kilovac S06FNA218 No Load Switching Features:
8 amp carry at DC; 6 amp carry at 30 MHz
Vacuum dielectric for low leakage current
applications
Highly reliable RF relay
100 million cycle mechanical life
Features:
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 26
7 kV
Kilovac S06HBA318 No Load Switching Features:
8 amp continuous carry @ 7 Kvdc
Vacuum dielectric for power switching low
current loads
100 million cycle mechanical life
Carries 10A at DC; 6 amps at 30 MHz
Features:
1.
31 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
8 kV
Kilovac S06JNB218 Make & Break Load Switching Features:
Highly reliable RF relay
Vacuum dielectric for power switching low
current loads
100 million cycle mechanical life
Form B relay
8 amps at DC; 6 amps at 30 MHz
Features:
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 34
28-1800Vdc
Features:
Kilovac EV4-1A Make Only
Excellent for electric vehicle controller main
capacitor pre-charge, (make & carry)
applications
PCB mounting
Rugged design for the most demanding
applications, including seismic shock
Small size and weight
Low power consumption
No heat sinks required
SF-6 gas-filled & sealed; can operate in
explosive and harsh environments
1000V isolation across open contacts
320 Vdc, 4 amp make/carry
Features:
11 Tyco Electronics / www.tycoelectronics.com / Factory Direct Technical Support: 800-253-4560, ext. 2023 (U.S., Canada, Mexico) or 805-220-2020, ext. 2023 (International)
12 kV
Kilovac H-14 Make & Break Load Switching Features:
Double pole, double throw contacts
Vacuum dielectric for power switching low
current loads
30 Amps DC continuous current rating
Corona shield high voltage terminals available
Meets requirements of MIL-R-83725
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 44
20 / 25 kV
Kilovac H-19 Make & Break Load Switching Features:
20 kV operating voltage
Vacuum dielectric and tungsten contacts for
power switching low current loads
Double pole, double throw contacts
Available with corona shield connectors
Meets requirements of MIL-R-83725
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 50
8 kV
Kilovac H-18 Make & Break Load Switching Features:
Smallest DPDT high voltage relay
Vacuum dielectric for power switching low
current loads
8 kV rating; carries 2 Amps at 32 MHz
Tungsten contacts for power switching low
current loads
Meets requirements of MIL-R-83725
Features:
37 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
30 kV
Kilovac H-23, H-24 Make & Break Load Switching Features:
(Not recommended for new designs) See K61 or K62 series for latest generation
products
Vacuum dielectric for power switching low
current loads
Features:
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 54
50 kV
Kilovac K64C Make Only Features:
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
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 56
15 kV
Kilovac H-26 Make & Break Load Switching Features:
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
Features:
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 48
3.5 kV
Kilovac HC-1 No Load Switching Features:
Kilovac HC-3 Make & Break Load Switching HC-1
Widely used for RF applications
Vacuum dielectric for low leakage current
applications
Copper contacts for high current capability
Not designed for power switching
Meets requirements of MIL-R-83725
QPL version available, M83725/5-001
HC-3
Tungsten contacts for long life when power
switching
Vacuum dielectric for power switching low
current loads
25 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
8 kV
Kilovac HC-2 No Load Switching Features:
HC-4 Make & Break Load Switching HC-2
Vacuum dielectric and copper contacts for
high current carry rating of 25 Amps
Not designed for power switching
Stable, low contact resistance
Meets requirements of MIL-R-83725
HC-4
Tungsten contacts for long life in power
switching applications
Vacuum dielectric for arc suppression when
making or breaking a load
Widely used in defibillator applications
Meets requirements of MIL-R-83725
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 36
5 kV
Kilovac K40P Make & Break Load Switching Features:
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
29 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
5 kV
Kilovac K41A, K41B Make & Break Load Switching Features:
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
27 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
5 kV
Kilovac K41P Make & Break Load Switching Features:
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
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 28
10 kV
Kilovac K43A, K43B Make & Break Load Switching Features:
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 version available, M83725/17 &
M83725/10
41 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
10 kV
Kilovac K43P Make & Break Load Switching Features:
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
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 42
8 kV
Kilovac K44P Make & Break Load Switching Features:
Single pole, single throw contacts with
latching actuator
Vacuum dielectric for power switching low
current loads
20 G vibration rating
Carries 50 amps at DC
Space rated versions available
Meets requirements of MIL-R-83725
Features:
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 38
5 kV
Kilovac K45C Make & Break Load Switching Features:
Small, low profile 5 kV relay
Vacuum dielectric for power switching low
current loads
Single pole, double throw contacts
Widely used in H.F. communication
equipment
Meets requirements of MIL-R-83725
Low power consumption
Features:
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 30
8 kV
Kilovac K47A Make & Break Load Switching Features:
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
35 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
35 kV
Kilovac K61A, K61B Make Only Features:
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
55 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
25 kV
Kilovac K62A, K62B Make & Break Load Switching Features:
25 kV relay with flying leads for ease of
installation
Vacuum dielectric and tungsten contacts for
power switching low current loads
Fully operable in air
Meets requirements of MIL-R-83725
51 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
70 kV
Kilovac K70A, K70B Make Only Features:
New, small, compact 70 kV relay package
SF-6 gas-filled for capacitive discharge and
high voltage isolation applications
Ideal for charging and discharging of high
voltage capacitors
Safe for use in adverse environments
57 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
10 kV
Kilovac K81A, K81B Make & Break Load Switching Features:
10 kV PC board-mount relay
Vacuum dielectric for power switching low
current loads
Flying leads or PCB mount for high voltage
connections
Meets requirements of MIL-R-83725
Completely sealed; ideal for test equipment
Panel mount available for ease of mounting
K81B Features:
39 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
10 kV
Kilovac K81C Make & Break Load Switching Features:
SPDT version of K81
Vacuum dielectric for power switching low
current loads
Flying Lead version will carry 10 Amps
continuous current
PCB mount version will carry 5 Amps
continuous current
Features:
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 40
15 kV
Kilovac KC-2 No Load Switching Features:
KC-8 Make & Break Load Switching KC-2
Vacuum dielectric for low and stable contact
resistance
Usable at frequencies above 32 MHz
Carries 50 Amps at DC; 10 Amps at 32 MHz
Not designed for power switching
KC-8
Not recommended for new design. See
KC-14 on page 45 for replacement.
KC-12
Not recommended for new design. See
KC-18 on page 45 for replacement.
Vacuum dielectric for power switching low
current loads
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 46
15 kV
Kilovac KC-14 Make & Break Load Switching Features:
Specifically designed for load switching
applications
Can power switch and isolate loads
Replaces Kilovac KC-8 & KC-12
Internal shield allows base to be grounded for load
switching below 500 Vdc
Meets requirements of MIL-R-83725 and SAE ARD
50031 for power switching
45 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
15 kV
Kilovac KC-15 Make Only Features:
SF-6 gas-filled for power switching on the
"make"
Long load life in capacitive discharge
applications
Recommneded for ESD testing and safety
interlock applications
Meets requirements of MIL-R-83725
47 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
25 kV
Kilovac KC-20 No Load Switching Features:
Rugged, high current carry ceramic relay
Carries 30 Amps at 32 MHz
Copper contacts; not designed for power
switching
Meets requirements of MIL-R-83725
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 52
25 kV
Kilovac KC-22, KC-32 Make & Break Load Switching Features:
KC-22
Tungsten contacts for power switching
Vacuum dielectric for arc suppression when
making or breaking a load
No contact oxidation from arcing
KC-32
Normally closed version of KC-22
Vacuum dielectric for power switching low
current loads
KC-38
Normally closed version of KC-28
SF-6 gas-filled for capacitive discharge and
make only applications
53 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
7.5 kV
Kilovac KM-13 Make Only Load Switching Features:
Highly reliable SF-6 gas-filled relay for
capacitive discharge applications
Widely used as heart defibrillator patient relay
Double pole, double throw contacts
CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com 32
7.5 kV
Kilovac KM-17 Make Only Load Switching Features:
Double pole, double throw contacts
SF-6 gas-filled for ideal discharge waveform
High voltage flying leads
Tabs for easy mount
Widely used in defibillator applications
Features:
33 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com
28-1800 Vdc
Kilovac PD10 Make & Break Load Switching Features:
Excellent for control applications
PCB and panel mountings
Rugged design for the most demanding
applications, including seismic shock
Small size and weight
Low power consumption
No heat sinks required
Vacuum-sealed; can operate in explosive and
harsh environments
2000V isolation across open contacts
Meets requirements of SAE ARD 50031
Vacuum dielectric for power switching
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.
CONTACT RATINGS*
100 140
28
60 150
10 200
1 600
* 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.
13 CII Technologies / P.O. Box 4422 / Santa Barbara, CA 93140 / ph 805.684.4560 / fax 805.684.9679 / e-mail info@kilovac.com / website www.ciitech.com