AEP16012 - Panasonic Electric Works

EP RELAYS

HIGH VOLTAGE AND

CURRENT CUT-OFF

CAPACITY IN A

COMPACT PACKAGE

150A 2 Form A

FEATURES

• Control of large voltages and

currents

The relays have a sealed construction

that is ﬁlled with a hydrogen gas

compound, and use a permanent magnet

to establish a magnetic path for the arc.

This allows them to switch high-level DC

voltages of up to 400V DC.

• Compact size and light weight

The capsule contact construction is ﬁlled

with a gas that has excellent thermal

dissipation and insulation characteristics.

Because of this we have been able to

reduce the contact gap to one tenth that

of conventional relays, and produce a

compact and light design.

• No arc space is required: size

including arc space 1/9 (compared to

conventional contactors)

The arc is not exposed to the outside,

therefore, no arc space is not required.

• Safety construction

The arc is not exposed, therefore, the

contactor is explosion proof and

intrinsically safe.

• Quiet: operation noise 1/4 (compared

to conventional contactors).

Along with the above-mentioned

miniaturization, the operation noise has

been reduced to 70dB, and, in addition,

the operation noise remains unchanged

when a current of 1000A or more is

interrupted.

• High contact reliability

The contact part is hermetically sealed,

hence the contact resistance remains

stable regardless of the ambient

conditions.

• Mounting direction is not speciﬁed

The weight of the movable parts is light,

and also the restoring force is large,

hence the contactor is relatively

unaffected by gravity.

• Line-up of indicator types (150A Type

only)

1 Form A and 1 Form B types with

indicators for detecting welding of the

main contacts are available.

• Line-up of PC board type and TM

type (10A type only)

• 12 and 24V DC coil voltage types are

available.

• Screw terminal blocks for easy

wiring.

TYPICAL APPLICATIONS

• AGV (Automatic guided vehicle)

(motor control)

• Electrical discharge machine

(capacitor charge and discharge

control)

• Inverter control (Error cut-off circuit)

• UPS (uninterruptible power supplies)

• Solar power generation systems

(battery control)

• Unmanned transport carts

• Battery inspection and testing

equipment

• Welding equipment

• Elevator (Brake control)

150A 1 Form A 60A

PC board type TM type

ORDERING INFORMATION

Product Name Contact arrangement Contact rating Coil voltage

Indicator contact

arrangement

EP 1: 1 Form A

2: 2 Form A

3: 1 Form A PC board type (10A type only)

5: 1 Form A TM type (10A type only)

1: 10A

5: 150A

6: 60A

12: 12V DC

24: 24V DC

48: 48V DC (10A type only)

X0: 100V DC (10A type only)

0: without indicator contact

1: a contact (150A type only)

3: b contact (150A type only)

Ex. A EP 1 5 0 12

TYPES AND COIL DATA (at 20

C 68

Note: *Same coil data as Indicator type.

When using a DC power supply use one that has a leeway of at least 150% current capacity.

Part No. Coil voltage,

V DC

Pick-up voltage,

V DC (max.)

(at 20

Drop-out voltage,

V DC (min.)

(at 20

Nominal coil current,

mA (

10%)

(at 20

Operating power,

W (12 V DC, at 20

Max. allowable

voltage,

V DC

AEP25012*

12 V DC 9 V DC 1 V DC 2.8 A (at peak)* 35W (Inrush, approx. 0.1S)

5W (Stable) 16 V DCAEP15012*

AEP16012 0.415 A Max. 5W

AEP25024*

24 V DC 18 V DC 2 V DC

1.9 A (at peak)* 35W (Inrush, approx. 0.1S)

Max. 5W (1 Form A)

Max. 6W (2 Form A) 32 V DCAEP15024* 2.2 A (at peak)*

AEP16024 0.208 A Max. 5W

AEP31012 12 V DC 9 V DC 0.75 V DC 0.103 A (at peak)*

Approx.1.4W

14 V DC

AEP31024 24 V DC 18 V DC 1.50 V DC 0.052 A (at peak)* 28 V DC

AEP31048 48 V DC 36 V DC 3.98 V DC 0.026 A (at peak)* 56 V DC

AEP310X0 100 V DC 75 V DC 8.3 V DC 0.012 A (at peak)* 116 V DC

AEP51012 12 V DC 9 V DC 0.75 V DC 0.103 A (at peak)*

Approx.1.4W

14 V DC

AEP51024 24 V DC 18 V DC 1.50 V DC 0.052 A (at peak)* 28 V DC

AEP51048 48 V DC 36 V DC 3.98 V DC 0.026 A (at peak)* 56 V DC

AEP510X0 100 V DC 75 V DC 8.3 V DC 0.012 A (at peak)* 116 V DC

Packing quantity SPARE PARTS

Types Inner Outer

150A 2 Form A 1pc. 5pcs.

150A 1 Form A 1pc. 10pcs.

60A 1 Form A 1pc. 20pcs.

10A 1 Form A 25pcs. 100pcs.

Installing parts Part No. Packing Quantity

M8 nut with washer for 150A type AEV801 2pcs.

M5 screw for 60A type AEV802 2pcs.

M4 screw for 30A type AEV803 2pcs.

Bus bar for 60A type AEV804 1pc.

SPECIFICATIONS

Contact

Notes:

Same speciﬁcations as the 12 V type.

#1 Condition: Nominal switching 100cycles, each cut off 2,500A

#2 Conditions: Varistor used for coil surge absorption. Note: if a diode is used the life will be lower.

Type 150A type 60A type 10A type

Arrangement 1 Form A, 2 Form A 1 Form A 1 Form A

Rating

Nominal switching capacity

(resistive load)

150A 400V DC

150A 277V AC

60A 400V DC

60A 277V AC 10A 400V DC

Short term current 300A (10min)

(harness wire: 40mm

)

120A (15min)

(harness wire: 15mm

)15A (2min), 30A (30s)

Max. cut-off current 2,500A 300V DC

(3 cycles)

600A 300V DC

(5 cycles) —

Overload opening/closing rating 600A 300V DC

(Min. 25 cycles)

180A 400V DC

(Min. 100 cycles)

30A 400V DC

(Min. 50 cycles)

Reverse cut-off current –300A 200V DC

(Min. 25 cycles)

–60A 200V DC

(Min. 1,000 cycles)

–10A 200V DC

(Min. 2.5

cycles)

Contact voltage drop (Max.)

0.1V

(When current

[is 150A per 1] contact set)

0.1V

(When current

[is 60A per 1] contact set)

0.5V

(When current

[is 10A per 1] contact set)

Nominal operating power

35W

(Inrush, approx 0.1s)

( Stable )

Max. 5W —

Expected life

(min. operations)

Mechanical 1 Form A: 10

2 Form A: 5

Electrical 3

150A 400V DC

(L/R

1ms)

60A 400V DC

(L/R

1ms

)

7.5

10A 400V DC

(L/R

1ms

)

Characteristics

Initial insulation resistance Min. 100 M

Ω

(at 500 V DC)*

Initial breakdown voltage Between open contacts AC 2,500 Vrms for 1 min.*

Between contact and coil AC 2,500 Vrms for 1 min.*

Operate time (at 20

C) (at nominal voltage) Max. 50ms*

Reset time (without diode) (at 20

C) (at nominal voltage) Max. 30ms*

Shock resistance Functional Min. 196 m/s

{20 G}*

Destructive Min. 490 m/s

{50 G}*

Vibration resistance Functional 43 m/s

{4.4 G} 10 to 200Hz*

Destructive 43 m/s

{4.4 G} 10 to 200 Hz*

Conditions for operation, transport and

storage (Not freezing and condensing

at low temperature)

Ambient temperature –40

C to +80

–40

F to +176

Humidity 5 to 85% R.H.

Unit weight

150 A 1 Form A: 600 g 21.16oz

150 A 2 Form A: 1,100 g 38.80oz

60 A: 340 g 12.00oz

10 A: 80 g 2.820oz

Remarks

*1 Measurement at same location as “Initial breakdown voltage” section.

*2 Detection current: 10mA.

*3 Nominal voltage applied to the coil,excluding bounce time.

*4 Nominal voltage applied to the coil.

*5 Half-wave pulse of sine wave: 11 ms; detection time: 10

*6 Half-wave pulse of sine wave: 6 ms.

*7 Detection time: 10

*8 3 directions,each 4 hours.

*9 Storage:Max.85

C 185

Indicator ratings

Note: Indicator type is only available for the 150 A type.

Arrangement 1 Form A 1 Form B

Material Gold-clad

Rating (resistive load) 0.1 A 30 V DC

Contact resistance Max. 100 m

Ω

mm inch

DIMENSIONS

150A 2 Form A

3.5

.138

27.0 1.063

66.0 2.598

96.0 3.780

±0.2

76.0 ±.008

2.992

.197

29.0

1.142

7.7

.303

Coil input terminal (M3.5)

5 terminal: input (+) side

6 terminal: input (–) side

.236

26.0

1.024

Plate (Part No., rating,

schematic and Lot No.)

20.0 .787 (terminal height)

26.0

1.024

13.0

.512

73.5 2.894 (terminal height)

87.1

3.429

M8 nut; AEV801

3-4

4- 5.5

±0.1

4- .217

±.004

±0.2

78.0±.008

3.071

90.0

3.543 9.5

.374

34.0

1.339

73.0

2.874

Schematic (TOP VIEW)

Mounting dimensions

6: Coil (–)

5: Coil (+)

2–

3–

Both input and load sides have polarities (+) and (–).

2.992

4- .217

4- 5.5

3.071

General tolerance:

less than 10 .394

0.3

.012

10 .394 to 50 1.969

0.6

.024

more than 50 1.969

1.0

.039

150A 2 Form A (Indicator Type)

3.5

.138

27.0 1.063

66.0 2.598

96.0 3.780

±0.2

76.0 ±.008

2.992

.197

29.0

1.142

26.0

1.024

13.0

.512

87.1

3.429

3-4

9.5

.374

7.7

.303

.236

78.0±0.2

3.071±.008

90.0

3.543

26.0

1.024

Coil input terminal (M3.5)

5 terminal: input (+) side

6 terminal: input (–) side

Plate (Part No., rating,

schematic and Lot No.)

20.0 .787 (terminal height)

73.5 2.894 (terminal height)

M8 nut; AEV801

4- 5.5

±0.1

4- .217

±.004

Indicator input

terminal (M3.5)

7 terminal: NO or NC

8 terminal: COM

34.0

1.339 73.0

2.874

Schematic (TOP VIEW)

1 Form A

1 Form B

Mounting dimensions

6: Coil (–)

5: Coil (+)

8: Indicator: COM

7: Indicator: NO

2–

3–

Both input and load sides have polarities (+) and (–).

2–

3–

Both input and load sides have polarities (+) and (–).

6: Coil (–)

5: Coil (+)

8: Indicator: COM

7: Indicator: NC

2.992

4- .217

4- 5.5

3.071

General tolerance:

less than 10 .394

0.3

.012

10 .394 to 50 1.969

0.6

.024

more than 50 1.969

1.0

.039

mm inch

150A 1 Form A

3.5

.138

27.0 1.063

64.0 2.520

±0.2

76.0 ±.008

2.992

94.0 3.701

19.5

.768

56.0

2.205

7.7

.303

9.5

.374

10.8

.425

.236

26.0

1.024

13.0

.512

87.1

3.429

M8 nut; AEV801

21.0

.827

1+2-

1+-2

Coil input terminal (M3.5)

5 terminal: input (+) side

6 terminal: input (–) side

Plate (Part No., rating,

schematic and Lot No.)

20.0 .787 (terminal height)

73.5 2.894 (terminal height)

2- 5.5

±0.1

2- .217

±.004

±0.2

44.0

±.008

1.732

29.0

1.142

Schematic (TOP VIEW)

Mounting dimensions

6: Coil (–)

5: Coil (+)

2–1+

Both input and load sides have polarities (+) and (–).

2.992

2- .217

2- 5.5

1.732

General tolerance:

less than 10 .394

0.3

.012

10 .394 to 50 1.969

0.6

.024

more than 50 1.969

1.0

.039

150A 1 Form A (Indicator Type)

3.5

27.0

64.0

±0.2

76.0

94.0

7.7

.303

9.5

.374

10.8

.425

.236

26.0

1.024

13.0

.512

87.1

3.429

1+2-

1+-2

21.0

.827

(9.5)

(.374)

Coil input terminal (M3.5)

5 terminal: input (+) side

6 terminal: input (–) side

Plate (Part No., rating,

schematic and Lot No.)

20.0 .787 (terminal height)

73.5 2.894 (terminal height)

2- 5.5

±0.1

2- .217

±.004

Indicator input

terminal (M3.5)

7 terminal: NO or NC

8 terminal: COM

M8 nut; AEV801

17.8

.701

19.5

.768

±0.2

44.0±.008

1.732

29.0

1.142

56.0

2.205

15.0 .591 (terminal height)

Schematic (TOP VIEW)

1 Form A

1 Form B

Mounting dimensions

6: Coil (–)

5: Coil (+)

2–1+

Both input and load sides have polarities (+) and (–).

8: Indicator: COM

7: Indicator: NO

6: Coil (–)

5: Coil (+)

2–1+

Both input and load sides have polarities (+) and (–).

8: Indicator: COM

7: Indicator: NC

2.992

2- .217

2- 5.5

1.732

General tolerance:

less than 10 .394

0.3

±.012

10 .394 to 50 1.969 ±0.6 ±.024

more than 50 1.969 ±1.0 ±.039

mm inch

60A

2.5 .098

(17.9) (.705)

45.0 1.772

49.0 1.929

61.0±0.2 2.402 ±.008

76.0 2.992

.512

±0.2

26.0±.008

1.024

30.2

1.189

38.0

1.496

7.7

.303

9.5

.374

6.55

.258

Coil input terminal (M3.5)

M4 screw: AEV803 (built-in)

63.9 2.516

79.9 3.146 M5 screw: AEV802

AEV804 (built-in)

Bus bar (15sq):

13.0

.512

71.0

2.795

26.0

1.024

2- 5.5

±0.1

2- .217

±.004

Plate (Part No., rating,

schematic and Lot No.)

20.0 .787

(terminal height)

62.0 2.441 (terminal height)

Schematic (TOP VIEW)

Mounting dimension

6: Coil

5: Coil

2–1+

Load side has polarities (+) and (–).

2.402

1.024 2- .217

2- 5.5

General tolerance:

less than 10 .394 ±0.3 ±.012

10 .394 to 50 1.969 ±0.6 ±.024

more than 50 1.969 ±1.0 ±.039

10A PC board type

34.0

1.339

31.3

1.232

31.6

1.244

19.5

.768

(1.0)

(.039)

0.5

.020

1.4

.055

3.0

.118

2 dia.

.079 dia. 2 dia.

.079 dia. 4.5 max.

.177 max.

62.4

2.457

55.9±0.3

2.201±.012

16.5±0.3

.650±.012

9.5±0.3

.374±.012

11.0±0.3

.433±.012 8.6±0.3

.339±.012

45.0

1.772

4.5

.177

R2.3 .091

37.9

1.492

Coil input terminal

Schematic (TOP VIEW)

Mounting dimensions

Notes: 1. We recommend through-hole plating

with land on both sides.

2. Be careful of the insulation distance

between land patterns with regards

to the circuit voltage you will use.

6:Coil

5:Coil

Load sides have polarities (+) and (–).

4-2.45 dia. 4-.096 dia.

After doing through-hole plating

Mounting hole

2-4.2 dia.

2-.165 dia.

9.5

.374 16.5

.650

55.9

2.201

8.6

.339

19.6

.772

+0.1

0+.004

General tolerance:

less than 10 .394 ±0.3 ±.012

10 .394 to 50 1.969 ±0.6 ±.024

more than 50 1.969 ±1.0 ±.039

mm inch

10A TM type

66.8

2.630

19.6

.772

19.5

.768

45.0

1.772

8.6

.339

Coil input terminal

#187 tab 0.5t

Load input terminal (–)

#187 tab 0.5t

Load input terminal (+)

#187 tab 0.5t

55.9±0.3

2.201±.012

14.1±0.3

.555±.012

4.5±0.2 dia.

.000±.008 dia.

11.3±0.3

.445±.012 37.9

1.492

31.7

1.248

5.7

.224

0.4

.016

45 max.

1.772 max.

31.6

1.244

Schematic (TOP VIEW)

Mounting dimensions

5:Coil

Load sides have polarities (+) and (–).

6:Coil

Mounting hole

2-4.2±0.1 dia.

2-.165±.004 dia.

55.9±0.1

2.201±.004

General tolerance:

less than 10 .394 ±0.3 ±.012

10 .394 to 50 1.969 ±0.6 ±.024

more than 50 1.969 ±1.0 ±.039

REFERENCE DATA

1-(1) Ambient temperature characteristics

(150 A type)

Sample: AEP15012, 3pcs

1-(2) Ambient temperature characteristics

Sample: AEP16012, 3pcs

1-(3) Ambient temperature characteristics

Sample: AEP51012, 3pcs

Pick up

voltage

Variation

ratio, %

Drop out

voltage

Ambient

temperature, °C °F

-40

-40 -20

-4 20

-6

-2

-4

-8

-10

110

74 80

146

-40

-40 -20

-4

-30

-10

-20

-40

110

74 80

146

Pick up

voltage

Variation

ratio, %

Drop out

voltage

Ambient

temperature °C °F

–40

–40 –20

–40

32 0

146

110

Pick up

voltage

Drop out voltage

–30

–40

–20

–10

Variation

ratio, %

Ambient

temperature °C °F

2. Max. switching capacity 3-(1) Switching life curve (150A, 60A type) 3-(2) Switching life curve (10A type)

101 100 1000

1000

100

Contact voltage, V

Contact current, A

150A type

DC, AC 400V resistive load

60A type

DC, AC 400V resistive load

10A type

DC, AC 400V resistive load

Contact current, V

Life (×103 cycle)

100 1000

100

150A type

DC, AC 400V resistive load

60A type

DC, AC 400V resistive load

110100

100000

10000

1000

100

10A type

DC, AC 400V resistive load

Contact current, V

Life (cycle)

4. Cut-off life curve 5. Carrying performance curve

Cut-off current, A

100 1000

10000

1000

100

150A type

DC400V resistive load

60A type

DC400V resistive load

Life (cycle)

Carrying current, A

100 1000

105

104

100

1000

150A type

(Electric cable 40mm2)

60A type

(Electric cable 15mm2)

Time (sec)

NOTES

1. When installing the relay, always

use washers to prevent loosening of

the screws.

Tighten each of the screws within the

rated ranges given below. Exceeding the

maximum torque may result in breakage.

Mounting is possible in either direction.

•M8 screw (150 A main terminal):

8 to 10 N·m

•M5 screw (150 A, 60 A main unit

mounting section): 2.5N·m to 3.6N·m

•M4 screw (60 A main terminal):

1.8 to 2.7 N·m

•M3.5 screw (Input terminal):

0.84 to 1.2 N·m

•M4 screw (10 A PC board type main

unit mounting section):

0.98N·m to 1.2N·m

(10 A TM type main unit mounting

section): 1.8N·m to 2.7N·m

The coils (150 A type) and the

contacts (10 A, 60 A, 150 A) of the relay

are polarized. Please follow instructions

in the connection schematic when

connecting the coils and contacts.

The 150 A type contains a reverse surge

voltage absorption circuit;

therefore a surge protector is not needed.

We recommend installing a surge

protector varistor (ZNR) for the 10 A and

the 60 A types. Avoid using a diode as

this may result in decreased cut-off

capability.

3. As a general rule, do not use a relay

if it has been dropped.

4. Avoid mounting the relay in strong

magnetic ﬁelds (near a transformer or

magnet) or close to an object that

radiates heat.

5. Electrical life

This relay is a high-voltage direct-current

switch. In its ﬁnal breakdown mode, it

may lose the ability to provide the proper

cut-off. Therefore, do not exceed the

indicated switching capacity and life.

(Please treat the relay as a product with

limited life and replace it when

necessary.)

In the event that the relay loses cut-off

ability, there is a possibility that burning

may spread to surrounding parts, so

conﬁgure the layout so that the power is

turned off within one second.

6. Permeation life of internal gas

This relay uses a hermetically encased

contact (capsule contact) with gas inside.

The gas has a permeation life that is

affected by the temperature inside the

capsule contact (ambient temperature +

temperature rise due to ﬂow of electrical

current). For this reason, make sure the

ambient operating temperature is

between –40 and 80°C –40 and +176°F,

and the ambient storage temperature is

between –40 and 85°C –40 and +185°F.

7. The case is designed to remain in

place during normal use and handling.

If the case is removed, the relay will not

function as intended and its performance

cannot be guaranteed.

8. If the power is turned off and then

immediately on after applying the

rated voltage (current) continuously to

the relay's coil and contact, the

resistance of the coil will increase due

to a rise in the coil temperature. This

causes the pick-up voltage to rise, and

possibly exceed the rated pick-up

voltage. In these circumstances, take

measures such as reducing the load

current, limiting the duration of

current ﬂow, and applying a coil

voltage higher than the rated

operating voltage (quick start).

9. Coil operating power

Pure DC current should be applied to the

coil. The wave form should be

rectangular. If it includes ripple, the ripple

factor should be less than 5%. However,

check the actual circuit since the

characteristics may be slightly different.

The coil must only be supplied with its

rated voltage. The voltage waveform

supplied to the coil should be rectangular.

10. Don't exceed maximum coil

voltage. Exceeding maximum

allowable coil voltage on continuous

basis will damage the relay and could

case failure.

11. Ensure that the rated contacts

voltage and current values are not

exceeded.

12. The rated control capacity and life

are given as guides.

The contact life is heavily inﬂuenced by

the type of load and other related

conditions, and these factors must be

kept in consideration when using the

relay.

13. If you are using an inductive load

(L load) such that L/R > 1 ms, add

surge protection in parallel with the

inductive load. If this is not done, the

electrical life will decrease and cut-off

failure may occur.

14. When using the 150 A type, mount

it as far away as possible from

Wireless transmitters or devices that

may generate large surges. To prevent

malfunctioning due to high emission

levels, it may be neccessary to take

measures for E.M.I., such as adding a

line noise ﬁlter or an electromagnetic

shield.

15. A slight amount of superimposed

line noise may be generated in the

input line the coil current control. It is

recommended to install a line ﬁlter to

reduce or eliminate this noise.

16. Ensure that the main terminals are

clean from oils and other foreign

matters. Contamination is likely to

cause increase in the terminal's

temperature.

•150A type: nominal cross sectional

area: min. 38mm2.

•60A type: nominal cross sectional area:

min. 14mm2.

•10A TM type: Faston terminal for #187

tab terminal, 0.5 mm board thickness

(JIS C2809-1992 compliant, ﬂat type

connection terminal)

Harness nominal cross sectional area

Load input terminal: min. 1.3 mm2

Coil input terminal: min. 0.3 mm2

17. Avoid excessive stress on the

terminals. Excessive stress can effect

the performance of the contact

operation.

•M8 screw terminal (150A main terminal

part)

Terminal pulling up strength ; Max.100N

per terminal

The up-down rotation torque applied to

the terminal ; Max.15N• m

18. Use 40N to 70N of force as a guide

to fasten the terminal connected to the

10A TM type. Please use caution when

inserting or removing the terminal as

the relay tab terminal may cause

injuly.

19. Place the PCB mount type (10A

PCB type) securely by hand soldering

after attaching it. Don't submerge

assembled board in cleaning solution

or water. Also, be careful not let ﬂux

overﬂow up from the PCB or adhere to

the base of the relay.

20. Make sure the power is turned off

when wiring.

21. Incorrect wiring may cause

unexpected malfunction and failure.

22. For AC cut-off, there is no contact

polarity. Conﬁrm electrical life using

actual load. In the case of DC cut-off,

please note the contact polarity.

23. Lead-free solder (tin, silver and

copper) is used as the spare solder for

the terminals of the PCB mount type

(10A PCB type).

For Cautions for Use, see Relay Technical Information.