KILOVAC EV200 Series Contactor With 1 Form X 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 nonoperation. Versatile coil/power connections. CE marked for EC applications. AIAG QS9000 designed, built and approved EV200 Series Contactor (CZONKA® Relay, Type III) File E208033 Typical EV200 applications include battery switching and back-up, DC voltage power control, circuit protection and safety. For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. Performance Data Parameter Units Value for EV200 Series Contact Arrangement, power contacts 1 Form X (SPST-NO-DM) Rated Operating Voltage VDC 12 - 900 Continuous (Carry) Current, Typical A 500 @ 85°C, 400 mcm conductors Consult Factory for required conductors for higher (500+ A) currents Make/Break Current at Various Voltages 1/ A See next page Break Current at 320VDC 1/ A 2,000, 1 cycle 3/ Contact Resistance, Typ. (@200A) mohms 0.2 Load Life Cycles See next page 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 Operate Time @ 25°C Close (includes bounce), Typ. ms 15 Bounce (after close only), Max. ms 7 Release (includes arcing), Max @ 2000A ms 12 Dielectric Withstanding Voltage Vrms 2,200 @ sea level (leakage <1mA) Insulation Resistance @ 500VDC megohms 100 2/ Shock, 11ms 1/2 sine, peak, operating G 20 Vibration, sine, 80-2000Hz., peak G 20 Operating Ambient Temperature °C -40 to +85 Weight, Nominal lb.(kg) .95 (.43) 1/ Main power contacts 50 at end of life 3/ Does not meet dielectric & IR after test, 1700 amp for unit with Aux. Contacts 2/ 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 Holding Current (Avg.) 0.13A@12V, 0.07A@24V 0.03A@48V 0.02A@72V Inrush Time (Max.) 130ms 130ms 130ms Part Numbering System Typical Part Number EV200 A Series: EV200 = 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 = 28VDC with Mechanical Economizer Coil Wire Length: A = 15.3 in (390 mm) B = 6.0 in (152 mm) Coil Terminal Connector: N = None B = Yazaki 7282-5558-10 male, 7114-4102-02, 7158-3030-50 +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 A A N A © 2004 & 2007 by Tyco Electronics Corporation. All Rights Reserved. KILOVAC, CZONKA, TE mark and TYCO ELECTRONICS are trademarks. Other products and company names mentioned herein may be trademarks of their respective owners. 1 Catalog EV200--R-TBD Revised 8-07 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 500+ Amp, 12-900VDC Contactor with 1 Form A (SPST-NO) Contacts 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) 2.58 ± .02 (65.6 ± .51) 3.17 ± .01 (80.48 ± .26) Estimated Make & Break Power Switching Ratings Make and Break Power Switching Region 100,000 Electrical Load Life Ratings for Typical EV Applications 650A Break Only Above 650A Make/Break Life Capacitive & Resistive Loads at 320VDC (1) (2) 10,000 Cycles 50,000 @80% capacitive pre-charge (make only) see chart below Cycles 50 @200A make/break (2 consecutive, reverse polarity) (1) Cycles 12 2,000A (break only) (1) Cycles 1* Cycles 1 million (1) Resistive load includes inductance L = 25µH. Load @ 2500A tested @ 200µH. (2) Life based on projected Weibull Life with 95% teliability. * Does not meet dielectric and IR after test. 120 VDC C VD VDC 100 @90% capacitive pre-charge (make only) see chart below Mechanical Life 900 400 Estimated Life (Cycles) 28 VDC C VD VDC 270 600 DC 0V 180 1,000 .5 ± .01 (12.6 ± .26) EV200 Capacitive Make Test Curves for Pre-Charged Motor Controller 700 650 10 600 80% Minimum Pre Charge 550 500 1 10 100 Load Current (A) 1,000 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 0 0.0 0.5 1.0 Time (ms) 1.5 2.0 For factory-direct application assistance, dial 800-253-4560, ext. 2055, or 805-220-2055. EV200--R-TBD – 0M – KRG – FP – 8-07 Printed in U.S.A. 2 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967