Smart Power Relay E-1048-8C... Description The Smart Power Relay E-1048-8C – is a remotely controllable electronic load disconnecting relay with three functions in a single unit: l electronic relay l electronic overcurrent protection l status and monitoring functions The 7 pin CUBIC version is designed for use with standard automotive relay sockets. A choice of current ratings is available from 1 A through 25 A. An operating voltage range of DC 9...32 V allows the connection of DC 12 V and DC 24 V loads. In order to switch and protect loads remotely, it has until now been necessary to connect several discreet components together - an electro-mechanic relay, control cable and integral contact to close the load circuit - an additional protective element (circuit breaker or fuse) for cable or equipment protection - a device for current measurement (shunt) Now type E-1048-8C combines all these functions in a single unit, thus minimising the number of connections in the circuit and thereby reducing the risk of failures. Applications Type E-1048-8C is suited to all applications with DC 12 V or DC 24 V circuits, where magnetic valves, motors or lamp loads have to be switched, protected and monitored: - road vehicles (utility vehicles, buses, special vehicles) - rail vehicles - marine industry (ships, boats, yachts etc.) The Power Relay is also suitable for industrial use (process control, machine-building, engineering) as an electronic coupling relay between PLC and DC 12 V or DC 24 V load Features l l l l l l l l Integral power electronics provide a wear-resistant switching function, insensitive to shock, vibration and dust. Compared to electro-mechanical relays, only a fraction of the closed-circuit current or switching current is needed. This is important for battery buffered load circuits which have to remain controlled even with the generator off line. The extremely low induced current consumption of less than 1 mA is absolutely necessary for battery buffered applications. The load circuit is disconnected in the event of an overload or short circuit. The load circuit is permanently monitored for wire breakage. Two status outputs for control signal AS and group signal SF provide status indication. For processing the actual value of the current flow in a power management system an analogue output from 0 to 5 V is provided. This voltage signal may also be used as an input to a control circuit or to switch off the unit by means of external control in the event of low load current value. For switching and monitoring loads of 25 A plus it is possible to connect several units in parallel. Uniform power distribution between units must be ensured by symmetrical design of the supply cables (length and cross section). Coloured label, for the identification the rated current (e. g. red = 10 A) E-1048-8C CUBIC version Technical Data (TA = 25 °C, UN) Power supply LINE + Type Voltage ratings UN Operating voltage US: Closed-circuit current I0 in the OFF condition DC power supply with small R i battery and generator etc. DC 12 V/DC 24 V DC 9...32 V < 1 mA Load circuit LOAD Load outputPower MOSFET, high side switching HSS Current rating range IN1 A ... 25 A (fixed rating) without load reduction up to 85° C (1 A...20 A), 25 A bis 60 °C ambient temperature IN = 1 A ... 10 A: trip curve 1 IN = 15 A ... 25 A: trip curve 2 Types of loads resistive, inductive, capacitive, lamp loads, motors (depending on duration of inrush current) Typical voltage drop UON at rated current IN IN 1A 2A 3A 5A 7.5 A Switching point 50 55 60 80 90 1) UON mV mV mV mV mV 1) IN 10 15 20 25 A A A A UON 110 mV 70 mV 90 mV 120 mV 5 typically 1.3 x IN (-40 °C...+85 °C: 1.1...1.5 x IN) Trip time1) typically 200 ms with switch-on onto overload and/or load increase on duty max. overload IN = 1 A ... 10 A: 60 A (at L/R = 3ms) IN = 15 A ... 25 A: 250 A (at L/R = 3ms) Temperature disconnection power transistor > 150 °C Parallel connection of channels for loads of 25 A plus, several units of identical current ratings may be connected in parallel. To ensure equal distribution of current between units, symmetrical design of the supply feed is necessary (length and cross section). Free-wheeling diode for connected load Delay time 1) integral IN = 1 A ... 10 A: 40 A IN = 15 A ... 25 A: 100 A ton 5 ms / toff 1.5 ms 1) typical 1651 www.e-t-a.de 1 Smart Power Relay E-1048-8C... Technical Data (TA = 25 °C, UN = DC 24 V) (TA = ambient temperature at UN) Wire breakage monitoring in wire breakage thresholds: ON and OFF in OFF-condition (ver.1): Rload > 100 kΩ condition of load 1) in OFF-condition (ver.2): Rload > 10 kΩ in ON-condition: Iload < 0.2 x IN indication via group fault signalisation SF (switching output) Fault indication will not be stored, i.e. after remedy of wire breakage fault indication will disappear Possible options: - wire breakage indication only in ON condition - wire breakage indication only in OFF condition - no wire breakage indication) Short circuit, overload - disconnection of load, indication via in load circuit group signal SF - no automatic re-start - after remedy of the fault unit has to be reset via control input IN+ Control input IN+ Control voltage IN+ 0...5 V = “OFF”, 8.5...32 V = “ON” Control current IE 1...10 mA (8.5...DC 32 V) Reset in the event of a failure -via external control signal (low-high) at control input IN+ - high) at control input IN+ - via reset of supply voltage Switching frequency at resistive or inductive load max. 60 Hz Edge of IN < 5 ms Status and diagnostic functions 5 Control signal AStransistor output low side switching (LSS), open collector, short circuit and overload proof, max. load: DC 32 V/2 A 0 V-level: when unit is set (at IN+ = 8.4...32 V) Group signal SFtransistor output low side switching (LSS), open collector, short circuit and overload proof, load max. DC 32 V/2 A 0 V-level with overload and short circuit disconnection, wire breakage indication Analogue output U(I) voltage output 0-5 V proportional to load current: 1 V = 0.2 x IN 5 V = 1.0 x IN 5 V... typically 6.5 V = overload range tolerance: (for Iload > 0.2 x IN) ± 8 % of IN max. output current 5 mA load resistance > 1 kΩ against GND Trip times 1) response time when switching on a load: definition of t90 t90 = 20 ms reached 90% of final value response time of load change on duty: t90 = 1 ms Visual status indication control signal AS group fault signal SF Technical Data (TA = 25 °C, UN = DC 24 V) (TA = ambient temperature at UN) Temperature range ambient temperature Temperature shutdown Tests 1...20 A: -40...+85 °C 25 A: -40...+60 °C without load reduction power transistor > 150 °C Humid heat combined test, 9 cycles with functional test test to DIN EN 60068-2-30, Z/AD Temperature change min. temperature -40 °C, max. temperature +90 °C test to DIN IEC 60068-2-14, Nb Vibration (random) in operation, with temperature change 6 g eff. (10 Hz...2,000 Hz) test to DIN EN 60068-2-64 Vibration was tested with standard sockets for PCB mounting. Behaviour at vibrations depends on design, quality and age (number of push-in cycles) of the socket particularly regarding duration of the vibration and the mounting position Shock 25 g/11 ms, 10 shocks test to DIN EN 60068-2-27 Corrosion test to DIN EN 60068-2-52, severity 3 Protection class housing -8C4 IP30 to DIN 40050 housing -8C5 IP54 to DIN 40050, higher protection class upon request EMC requirements EMC directive: emitted interference EN 50081-1 noise immunity EN 61000-6-2 Automotive directive: emitted interference, noise immunity: 72/245/EWG und 2006/28/EG Terminals of CUBIC version (7 pin, standard) Mounting: 5 blade terminals 6.3 mm x 0.8 mm and 2 blade terminals 2.8 mm x 0.6 mm to DIN 46244 Contact material CuZn37F44 on automotive relay socket 4-pole or 7-pole Housing CUBIC version max. dimensions Materials Mass 30 x 30 x 40 mm when plugged in 30 x 30 x 51.6 mm including terminals housing PA66-GF30 base plate PA6-GF30 approx. 23 g...43 g, depending on version Approvals CE, E1 logo to EMC directive and vehicles directive Approved by Kraftfahrt-Bundesamt approvals no. E1 10R-043880 LED yellow LED red General data Reverse polarity protection Control circuit yes Load circuit no (due to integral free-wheeling diode) Status outputs interference voltage resistance max. DC 32 V 1) typically 2 www.e-t-a.de 1651 Smart Power Relay E-1048-8C... Dimensions „DELUXE“ version (7 pin version) Type E-1048-8C E-1048-8C 4 - C 3 D 4 V1 - 4 U3 - 20 A ordering example 1: 7 pole version E-1048-8C 4 - C 0 A 0 V0 - 4 U3 - 5 A ordering example 2: 4 pole version with all options: - LED indications AS/SF - status outputs AS/SF - analogue output U (I) 3 2 6 1 5 2, 4, 5, 6 and 8 - blade terminals 6.3 x 0.8 1 and 3 - blade terminals 2.8 x 0.6 4 8 40 1.57 footprint to ISO 7588 30 1.18 30 1.18 Smart Power Relay DC 12 V/24 V - 1 A...25 A in CUBIC version Housing / temperature range 4 with housing -40 °C...85 °C (60 °C at IN = 25 A) 5 with housing -40 °C...85 °C (60 °C at IN = 25 A) increased environmental requirements (IP protection class etc.) Control input C with control input (+ control 8.5...32 V) LEDs 0 without 3 2 LEDs: AS yellow, SF red Status output minus-switching A without D with AS and SF Contents of group fault signal SF/ LED indication SF 0 without 1 short circuit / overload 4 short circuit / overload + wire breakage Analogue output V0 without V1 0...5 V Characteristic curve 4 200 ms standard switch-off delay with overload) Voltage rating U3 DC 12/24 V Current ratings / colour of label 1 A / black 2 A / grey 3 A / purple 5 A / light-brown 7.5 A / brown 10 A / red 15 A / blue 20 A / yellows 25 A / white 51.6 2.03 Ordering Information LED yellow LED red Dimensions „BASIC Version“ (4 pin version) without options: - LED indication AS/SF - status outputs AS/SF - analogue output U (I) Preferred types Preferred types 2 Standard current ratings (A) E-1048-8C4-C3A1V0-4U3- 5 7.5 10 15 20 25 x x x x x x 6 5 2, 4, 6 and 8 - blade terminals 6.3 x 0.8 4 8 Approvals footprint to ISO 7588 Approval mark Regulation KBA E1 ECE R 10 51.6 2.03 40 1.57 Authority 30 1.18 30 1.18 This is a metric design and millimeter dimensions take precedence ( mm ) inch 1651 www.e-t-a.de 3 Smart Power Relay E-1048-8C... Typical time/current characteristics (TU = 25 °C) Connection diagram LINE (+) DC 12 V/24 V Trip curve 1: 1 A, 2 A, 3 A, 5 A, 71/2 A and 10 A (standard 200 ms) AS* yellow SF* red 1000 control input group fault signal 100 Trip time in ms control signall analogue output 0 … 5 V 10 max. 6,5 V LOAD (+) 1 = IN+ 1…10 mA SF * AS * U(I) * max. 2 A max. 2 A max. 5 mA GND * Optionally available: - LED indication AS / SF - status outputs AS / SF - analogue output U(I) max. overload 0.1 0 1 2 typ. 1.3 x IN (typ. 60 A) I (A) Pin selection CUBIC version (7 pin = “DELUXE”) ... times rated current IN Trip curve 2: 15 A, 20 A and 25 A (standard 200 ms) 1000 E-1048-8C CUBIC version Trip time in ms 100 10 AS 1 control signal ( ^ = LED yellow) LINE + 2 (30) SF 3 plus US (DC 12 V/24 V) ^ LED red) group fault signal (= IN+ 4 (86) control input U(I) 5 0…5 V analogue output GND 6 (31) minus US LOAD 8 (88a) load output 3 2 (30) 1 5 6 4 (31) (86) 8 (88a) ^ automotive terminal labeling ()= 5 1 Pin selection CUBIC version (4 pin = “BASIC”) max. overload 0.1 0 1 2 typ. 1.3 x IN ... times rated current IN (typ. 250 A) I (A) E-1048-8C CUBIC version 1 LINE + 2 (30) plus US (DC 12 V/24 V) 3 IN+ 4 (86) control input 5 GND LOAD 6 (31) minus US 8 (88a) load output 2 (30) 6 (31) 4 (86) 8 (88a) ^ ()= automotive terminal labeling All dimensions without tolerances are for reference only. In the interest of improved design, performance and cost effectiveness the right to make changes in these specifications without notice is reserved. Product markings may not be exactly as the ordering codes. Errors and omissions excepted. 4 www.e-t-a.de 1651