DC Power Relays (60-A, 100-A Models) G9EA-1 DC Power Relays Capable of Interrupting High-voltage, High-current Loads • A compact relay (73 x 36 x 67.2 mm (L x W x H)) capable of switching 400-V 60-A DC loads. (Capable of interrupting 600 A at 300 VDC max.) • The switching section and driving section are gas-injected and hermetically sealed, allowing these compact relays to interrupt high-capacity loads. The sealed construction also requires no arc space, saves space, and helps ensure safe applications. • Downsizing and optimum design allow no restrictions on the mounting direction. • Terminal Cover and DIN Track Adapters are also available for industrial applications. • UL/CSA standard UL508 approved. Note: Refer to Precautions on page 22. Model Number Structure ■ Model Number Legend G9EA-@-@-@-@ 1 2 3 4 1. Number of Poles 1: 1 pole 2. Contact Form Blank: SPST-NO 3. Coil Terminals B: M3.5 screw terminals Blank: Lead wire output 4. Special Functions CA: High-current conduction (100 A) Ordering Information ■ List of Models Models Terminals Coil terminals Switching/current con- Screw terminals (See note 2.) duction models Lead wires High-current conduction models Contact form Rated coil voltage Model Contact terminals Screw terminals (See note 1.) Screw terminals (See note 2.) Lead wires SPST-NO 12 VDC 24 VDC 48 VDC 60 VDC 100 VDC G9EA-1-B G9EA-1 G9EA-1-B-CA G9EA-1-CA Note: 1. Two M5 screws are provided for the contact terminal connection. 2. Two M3.5 screws are provided for the coil terminal connection. DC Power Relays (60-A, 100-A Models) G9EA-1 5 Specifications ■ Ratings Coil Rated voltage Rated current Coil resistance Must-operate voltage Must-release voltage Maximum voltage (See note 3.) Power consumption 12 VDC 417 mA 28.8 Ω 24 VDC 208 mA 115.2 Ω 48 VDC 102 mA 469.3 Ω 60 VDC 86.2 mA 695.7 Ω Approx. 5.2 W 100 VDC 53.6 mA 1,864 Ω Approx. 5.4 W 75% max. of rated voltage 8% min. of rated voltage 130% of rated volt- Approx. 5 W age (at 23°C within 10 minutes) Note: 1. The figures for the rated current and coil resistance are for a coil temperature of 23°C and have a tolerance of ±10%. 2. The figures for the operating characteristics are for a coil temperature of 23°C. 3. The figure for the maximum voltage is the maximum voltage that can be applied to the relay coil. Contacts Item Resistive load G9EA-1(-B) G9EA-1(-B)-CA Rated load 60 A at 400 VDC, 100 A at 120 VDC 30 A at 400 VDC Rated carry current 60 A 100 A Maximum switching voltage 400 V 400 V Maximum switching current 100 A 30 A ■ Characteristics Item G9EA-1(-B) G9EA-1(-B)-CA Contact resistance (See note 2.) 30 mΩ max. (0.6 mΩ typical) 10 mΩ max. (0.3 mΩ typical) Contact voltage drop 0.1 V max. (for a carry current of 60 A) 0.1 V max. (for a carry current of 100 A) Operate time 50 ms max. Release time 30 ms max. Insulation resistance (See note 3.) Dielectric strength Between coil and contacts 1,000 MΩ min. Between contacts of the same polarity 1,000 MΩ min. Between coil and contacts 2,500 VAC, 1 min Between contacts of the same polarity 2,500 VAC, 1 min Impulse withstand voltage (See note 4.) 4,500 V Vibration resistance Destruction 10 to 55 to 10 Hz, 0.75-mm single amplitude (Acceleration: 2.94 to 88.9 m/s2) Malfunction 10 to 55 to 10 Hz, 0.75-mm single amplitude (Acceleration: 2.94 to 88.9 m/s2) Destruction 490 m/s2 Malfunction 196 m/s2 Shock resistance Mechanical endurance (See note 5.) 200,000 ops. min. Electrical endurance (See note 6.) 120 VDC, 100 A, 3,000 ops. min. 400 VDC, 30 A, 1,000 ops. min. 400 VDC, 60 A, 3,000 ops. min. 120 VDC, 30 A, 2,500 ops. min. 400 VDC, 30 A, 30,000 ops. min. --- Short-time carry current 100 A (10 min) 150 A (10 min) Maximum interruption current 600 A at 300 VDC (5 times) --- Overload interruption 180 A at 400 VDC (100 times min.) 100 A at 120 VDC (150 times min.) Reverse polarity interruption −60 A at 200 VDC (1,000 times min.) --- Ambient operating temperature −40 to 70°C (with no icing or condensation) Ambient operating humidity 5% to 85% Weight Approx. 310 g Note: 1. 2. 3. 4. 5. 6. 6 The above values are initial values at an ambient temperature of 23°C unless otherwise specified. The contact resistance was measured with 1 A at 5 VDC using the voltage drop method. The insulation resistance was measured with a 500-VDC megohmmeter. The impulse withstand voltage was measured with a JEC-212 (1981) standard impulse voltage waveform (1.2 × 50 µs). The mechanical endurance was measured at a switching frequency of 3,600 operations/hr. The electrical endurance was measured at a switching frequency of 60 operations/hr. DC Power Relays (60-A, 100-A Models) G9EA-1 Engineering Data ■ G9EA-1(-B) Switching/Current Conduction Models 500 G9EA-1 DC resistive load 100 10 5 Switching 120-VDC resistive load (positive direction) 3 Operations 1,000 300 Electrical Endurance (Interruption Performance) Electrical Endurance (Switching Performance) Operations (x 10,000) Switching current (A) Maximum Switching Capacity 10,000 5,000 3,000 1,000 500 300 1 50 0.5 30 0.3 10 0.1 5 0.05 10 3 0.03 5 3 Switching 400-VDC resistive load (positive direction) 100 50 30 1 0.01 1 10 30 50 100 300 10 500 1,000 Interrupting 400-VDC resistive load (positive direction) 30 50 100 300 500 1,000 10 30 50 100 300 500 1,000 Switching current (A) Switching current (A) Switching voltage (V) Energizing time (s) Carry Current vs Energizing Time 100,000 10,000 1,000 100 10 1 10 30 50 100 300 500 1,000 Carry current (A) ■ G9EA-1(-B)-CA High-current Conduction Models Electrical Endurance (Switching Performance) 1,000 500 300 100 G9EA-1-CA DC resistive load 10,000 5,000 3,000 Switching 120-VDC resistive load (positive direction) 1,000 50 500 30 300 10 100 5 50 3 30 Carry Current vs Energizing Time Energizing time (s) Operations Contact current (A) Maximum Switching Capacity 100,000 10,000 1,000 100 1 10 1 10 10 30 50 100 300 500 1,000 Switching voltage (V) 10 30 50 100 300 500 1,000 10 30 Switching current (A) DC Power Relays (60-A, 100-A Models) 50 100 300 500 1,000 Carry current (A) G9EA-1 7 ■ All G9EA-1 Models Must-operate voltage Sample: G9EA-1 Number: 35 Must-release voltage 25 20 20 Vibration Malfunction Operate time Sample: G9EA-1 Number: 35 Release time 15 Single amplitude (mm) 30 Time Characteristic Distributions Number of contacts Number of Relays Must-operate Voltage and Must-release Voltage Distributions 10 15 1 Sample: G9EA-1 0.9 Number: 5 Unconfirmed area 0.8 0.7 0.6 0.5 Confirmed area 0.4 10 0.3 5 0.2 5 0.1 0 40 60 80 100 5.0 0 10.0 15.0 20.0 25.0 Rate of change (%) 10.0 8.0 4.0 X Y' Y Y X' 600 X Z 400 Must-release voltage −6.0 Z' −8.0 X' 600 100 8.0 Sample: G9EA-1 Number: 5 6.0 4.0 2.0 Must-release voltage −6.0 −8.0 Energized After test Start Characteristics were measured after applying vibration at a frequency of 10 to 55 Hz (single amplitude of 0.75 mm) to the test piece (not energized) for 2 hours each in 3 directions. The percentage rate of change is the average value for all of the samples 50 −4.0 400 800 −10.0 10.0 −2.0 200 Deenergized 30 Must-operate voltage Must-operate voltage −4.0 10 0.0 200 0.0 8 Z 1,000 800 −2.0 5 Shock Resistance Z' Y 6.0 2.0 3 Frequency (Hz) Shock Malfunction Unit: m/s2 Sample: G9EA-1 Number: 5 Sample: G9EA-1 Number: 5 1 Time (ms) Percentage of rated voltage (%) Vibration Resistance 30.0 Rate of change (%) 20 0 1,000 Y' The value at which malfunction occurred was measured after applying shock to the test piece 3 times each in 6 directions along 3 axes. DC Power Relays (60-A, 100-A Models) G9EA-1 −10.0 After test Start Characteristics were measured after applying a shock of 490 m2/s to the test piece 3 times each in 6 directions along 3 axes. The percentage rate of change is the average value for all of the samples. Dimensions Note: All units are in millimeters unless otherwise indicated. Models with Screw Terminals G9EA-1-B(-CA) Terminal Arrangement/ Internal Connections (TOP VIEW) Two, M5 1(+) 1(+ 2(- 24 ) 36 Two, M3.5 screws ) 2(−) T: AC DC NT 0V COA 40 60 B -1EA G9VDJACPAN 01 -00 K1 12E IN 62 D MA 2 7 13 o. tN Lo Note: Be sure to connect terminals with the correct polarity. Coils do not have polarity. 47 61 73 Two, 6.2-dia. holes Mounting Hole Dimensions (TOP VIEW) Two, M6 or 6.5-dia. holes 15.3 15.2 1(+) 2(-) Dimension (mm) 8 17.5 Tolerance (mm) 10 or lower ±0.3 10 to 50 ±0.5 50 or higher ±1 G9EA-1-B 12VDC CONTACT: 60A 400VDC MADE IN JAPAN 39.7 (Coil terminal height) 67.2 60.7 (Terminal height) 61±0.1 Lot No. 1362K1-0001 10.5 24±0.1 Models with Lead Wires G9EA-1(-CA) Terminal Arrangement/ Internal Connections (TOP VIEW) Two, M5 ) 1(+ 1 (+) ) 2(- -1 EA G9 DCPAN 12VIN JA DE MA Lot No. T: AC DC NT CO 400V 60A 24 0001 36 K1- 1362 2 (−) 2 7 17.5 47 61 73 Two, 6.2-dia. holes 8 Note: Be sure to connect terminals with the correct polarity. Coils do not have polarity. Mounting Hole Dimensions (TOP VIEW) 15.2 (10) 1(+) 2(-) Dimension (mm) Two, M6 or 6.5-dia. holes 15.3 230±20 Tolerance (mm) 10 or lower ±0.3 10 to 50 ±0.5 50 or higher ±1 7 8 G9EA-1 12VDC MADE IN JAPAN CONTACT: 60A 400VDC 67.2 60.7 (Terminal height) 61±0.1 Lot No. 1362K1-0001 10.5 24±0.1 DC Power Relays (60-A, 100-A Models) G9EA-1 9 ■ Options Terminal Cover P9EA-C 17* P9 EA -C MA DE IN JA P >P AN C< C-A 36 Note: Be sure to remove the cutouts for wiring that are located in the wiring outlet direction before installing the Terminal Cover. Dimension (mm) E9 NA < C PAJ N P> I ED 31 13.2* P 21 6 AM 17* 17* 49 Tolerance (mm) 10 or lower ±0.3 10 to 50 ±0.5 50 or higher ±1 * Dimensions of cutouts for wiring. DIN Track Adapter P9EA-D P9EA-D Two, M5 61±0.1 88 Dimension (mm) 24±0.1 50 10 DC Power Relays (60-A, 100-A Models) G9EA-1 12 Tolerance (mm) 10 or lower ±0.3 10 to 50 ±0.5 50 or higher ±1 Precautions WARNING Take measures to prevent contact with charged parts when using the Relay for high voltages. ■ Precautions for Correct Use Refer to the relevant catalog for common precautions. 1. Be sure to tighten all screws to the appropriate torque given below. Loose screws may result in burning due to abnormal heat generation during energization. • M8 screws: 8.82 to 9.80 N·m • M6 screws: 3.92 to 4.90 N·m • M5 screws: 1.57 to 2.35 N·m • M4 screws: 0.98 to 1.37 N·m • M3.5 screws: 0.75 to 1.18 N·m 2. The G9EA and G9EC Relays’ contacts have polarity. Be sure to perform connections with the correct polarity. If the contacts are connected with the reverse polarity, the switching characteristics specified in this document cannot be assured. 3. Do not drop or disassemble this Relay. Not only may the Relay fail to meet the performance specifications, it may also result in damage, electric shock, or burning. 4. Do not use these Relays in strong magnetic fields of 800 A/m or higher (e.g., near transformers or magnets). The arc discharge that occurs during switching may be bent by the magnetic field, resulting in flashover or insulation faults. 5. This Relay is a device for switching high DC voltages. If it is used for voltages exceeding the specified range, it may not be possible to interrupt the load and burning may result. In order to prevent fire spreading, use a configuration in which the current load can be interrupted in the event of emergencies. In order to ensure safety of the system, replace the Relay on a regular basis. 6. If the Relay is used for no-load switching, the contact resistance may increase and so confirm correct operation under the actual operating conditions. 7. These Relays contain pressurized gas. Even in applications with low switching frequencies, the ambient temperature and heat caused by arc discharge in the contacts may allow permeation of the sealed gas, resulting in arc interruption failure. In order to ensure safety of the system, replace Relays on a regular basis. 8. Do not use or store the Relay in a vacuum. Doing so will accelerate deterioration of the sealing. 9. With this Relay, if the rated voltage (or current) is continuously applied to the coil and contacts, and then turned OFF and immediately ON again, the coil temperature, and consequently the coil resistance, will be higher than usual. This means that the must operate voltage will also be higher than usual, exceeding the rated value (“hot start”). In this case, take the appropriate countermeasures, such as reducing the load current or restricting the energizing time or ambient operating temperature. 10.The ripple percentage for DC relays can cause fluctuations in the must-operate voltage or humming. For this reason, reduce the ripple percentage in full-wave rectified power supply circuits by adding a smoothing capacitor. Ensure that the ripple percentage is less than 5%. 11.Ensure that a voltage exceeding the specified maximum voltage is not continuously applied to the coil. Abnormal heating in the coil may shorten the lifetime of the insulation coating. 12.Do not use the Relay at a switching voltage or current greater than the specified maximum values. Doing so may result in arc discharge interruption failure or burning due to abnormal heating in the contacts. 22 DC Power Relay Common 13.The contact ratings are for resistive loads. The electrical endurance with inductive loads is inferior to that of resistive loads. Confirm correct operation under the actual operating conditions. 14.Do not use the Relay in locations where water, solvents, chemicals, or oil may come in contact with the case or terminals. Doing so may result in deterioration of the case resin or abnormal heating due to corrosion or contamination of the terminals. Also, if electrolyte adheres to the output terminals, electrolysis may occur between the output terminals, resulting in corrosion of the terminals or wiring disconnections. 15.Be sure to turn OFF the power and confirm that there is no residual voltage before replacing the Relay or performing wiring. 16.The distance between crimp terminals or other conductive parts will be reduced and insulation properties will be lowered if wires are laid in the same direction from the contact terminals. Use insulating coverings, do not wire in the same direction, and take other measures as required to maintain insulation properties. 17.Use either a varistor, or a diode plus Zener diode as a protective circuit against reverse surge in the relay coil. Using a diode alone will reduce the switching characteristics. 18.Be sure to use the screws provided with the product for wiring coil terminals and contact terminals. The specified tightening torque cannot be achieved with different screws and may result in abnormal heat generation when energized. Recommended Wire Size Model Size G9EA-1(-B) 14 to 22 mm2 G9EA-1(-B)-CA 22 to 38 mm2 G9EC-1(-B) 38 to 60 mm2 G9EB-1-B 2 to 5.5 mm2 Note: Use flexible leads. Precautions