KILOVAC High Voltage
Relays and Contactors
7
PAGE 1
KILOVAC High Voltage Relays and Contactors
Table of Contents
High Voltage DC Contactors
Quick Reference Guide ..............................................7-4, 7-5
MAP Aerospace Military Contactors
MAP101 Series ..................................................7-6, 7-7
MAP100 Series ..................................................7-8, 7-9
MAP200 Series ................................................7-10, 7-11
MAP201 Series ................................................7-12, 7-13
CAP Aerospace Commercial
CAP202 Series .................................................7-14, 7-15
CAP200 Series .................................................7-16, 7-17
CAP120 Series .................................................7-18, 7-19
Higher Power and Sensing Contactors
KHR500 Series .................................................7-20, 7-21
K1K Series ....................................................7-22, 7-23
KCS01 Series ..................................................7-24, 7-27
KCS03 Series ..................................................7-28, 7-32
EV OEM/Commercial & Electric Vehicle
EV202 Series ..................................................7-33, 7-34
EV200A Series .................................................7-35, 7-36
EV200B Series .................................................7-37, 7-38
EV200P Series .................................................7-39, 7-40
EV100 Series ..................................................7-41, 7-42
LEV Industrial Commercial
LEV100 Series ................................................7-43 – 7-45
LEV100H Series ...............................................7-46 – 7-47
LEV200 Series .................................................7-48, 7-49
AC Contactors
FM200 Series ..................................................7-50, 7-51
Traditional 270 Vdc Aerospace Contactors
AP90X Series ..................................................7-52, 7-53
AP150X Series ......................................................7-54
AP265X Series, AP265P Series .........................................7-55
AP350X Series ......................................................7-56
Traditional 28 Vdc to 1800 Vdc Contactors
EV250 Series .................................................7-57 – 7-60
EV500 Series ..................................................7-61, 7-62
PD350X Series ......................................................7-63
KILOVAC High Voltage Relays and Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
Table of Contents (Continued)
High Voltage Relays
Quick Reference Guide ............................................7-65, 7-66
270 Vdc Aerospace Relays
AP5A Series, AP5B Series, AP5C Series, AP5P Series, AP5R Series .....7-67 – 7-69
AP10A Series, AP10B Series, AP10P Series, AP11A Series ............7-67 – 7-69
AP44P Series .......................................................7-70
28 Vdc to 1800 Vdc Relays
PD5A Series, PD5B Series, PD5C Series .................................7-71
PD10A Series, PD10B Series, PD10P Series ..............................7-72
1.5 - 2.0 kV Relay
K45C Series ........................................................7-73
3.5 kV Relays
HC-1 Series ........................................................7-74
HC-3 Series ........................................................7-74
HC-5 Series ........................................................7-74
5.0 kV Relays
K41A, K41B Series ...................................................7-75
K41C Series ........................................................7-75
K41P Series ........................................................7-76
K41R Series ........................................................7-76
K40P Series ........................................................7-77
K40P364 Series .....................................................7-77
7.5 kV Relays
KM-17 .............................................................7-78
8.0 kV Relays
K47A Series ........................................................7-79
K47B Series ........................................................7-79
HC-2 Series ........................................................7-80
HC-6 Series ........................................................7-80
.7-81H-18 Series .......................................................
K44P Series ........................................................7-82
10 kV Relays
K81A and K81B Series ................................................7-83
K81C Series ........................................................7-84
K43A, K43B and K43C Series ..........................................7-85
K43P and K43R Series ...............................................7-86
12 kV Relays
H-14 and H-16 Series .................................................7-87
KILOVAC High Voltage
Relays and Contactors
7
PAGE 3
KILOVAC High Voltage Relays and Contactors
Table of Contents (Continued)
15 kV Relays
H-8 Series .........................................................7-88
KC-14 Series .......................................................7-89
KC-18 Series .......................................................7-89
KC-2 Series ........................................................7-90
KC-11 Series .......................................................7-90
KC-12 Series .......................................................7-90
KC-15 and KC-16 Series ..............................................7-91
H-26 Series ........................................................7-92
20/25 kV Relays
H-19 and H-17 Series .................................................7-93
25 kV Relays
K62A, K62B and K62C Series ..........................................7-94
KC-20 Series .......................................................7-95
KC-30 Series .......................................................7-95
KC-22, KC-32 Series .................................................7-96
KC-28, KC-38 Series .................................................7-96
H-23 and H-24 Series .................................................7-97
35 kV Relays
KP61 Series ........................................................7-98
K60C Series ........................................................7-99
K61A and K61B Series ...............................................7-100
K61C Series .......................................................7-100
50 kV Relays
K64C Series .......................................................7-101
H-25 Series .......................................................7-101
70 kV Relays
K70A and K70B Series ...............................................7-102
K70C Series .......................................................7-102
Mounting Methods .....................................................7-103
Special Connectors ..............................................7-104, 7-104
Application Notes for EV/LEC Contactors ...........................7-106, 7-107
Application Notes for MAP/CAP Contactors ........................ 7-108 to 7-109
Application Notes on Coil Power Economizing using PWM Circuits ......7-110, 7-111
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
KILOVAC High Voltage DC Contactors Quick Reference Guide
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
(MAP) (CAP) (EV) (LEV)
Aerospace Military Aerospace Commercial OEM/Commercial &Electric Vehicle Industrial Commercial
Product Series MAP101 MAP100 MAP200 MAP201 CAP202 CAP200 CAP100 EV200A EV200B EV200P EV100 LEV100 LEV200
Main Contact Data
Continuous Current A 100 100 500 350 300 500 100 500 500 500 100 100 500
Contact Voltage Range Vdc 12-900 12-900 12-900 12-900 12-900 12-900 12-900 12-900 12-900 12-900 12-900 900 12-900
Electrical Life at Rated Current, Cycles 25,000 15,000 1,000 5,000 10,000 1,000 6,000 1,000 500 500 6,000 6,000 1,000
270 Vdc, Resistive Load
Overload (Make/Break) @ 350 Vdc A 2,000/2,000 500/1,500 650/2,000 2,000/2,000 650/2,000 650/2,000 600/1000 650/2000 650/1000 650/1000 600/1000 600/1000 650/2000
Rupture (Break only) @ 350 Vdc A 2,000 1,500 2,000 2,000 2,000 2,000 1000 2000 1000 1000 1000 1000 1000
Contact Arrangement SPST SPST SPST SPST DPST SPST SPST SPST SPST SPST SPST SPST SPST
Contact Form Latch X (NO) X (NO) X (NO) 2X (NO) X (NO) X (NO) X(NO) Y(NC) X (LATCH) X(NO) X(NO) X(NO)
or Latch
Contact Resistance @ Rated Current milliohms 0.75 0.5 0.2 0.3 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
Auxiliary Contact Data
Contact Form/Quantity of Sets (Max.) Form A/1 Form A/1 Form A/1 Form A/1 Form C/4 Form A/2 Form C/1 Form A/1 Form A/1 Form A/1 None Form X/1 Form X/1
Current Rating @ 30 Vdc (Ag/Au), Max. A 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1
Minimum Signal Level Vdc/mAdc Ag 6V/15mA Ag 6V/15mA Ag 6V/15mA Ag 6V/15mA Ag 6V/15mA Ag 6V/15mA Ag 6V/15mA Ag 6V/15mA Ag 6V/15mA Ag 6V/15mA — — Ag 6V/15mA
Au 5V/5mA Au 5V/5mA Au 5V/5mA Au 5V/5mA Au 5V/5mA Au 5V/5mA Au 5V/5mA Au 5V/5mA Au 5V/5mA Au 5V/5mA Au 5V/5mA
Dielectric Withstanding Voltage
Contacts to Coil to All Other Points Vrms 1,500 1,500 2,200 2,200 2,200 2,200 2,200 2,200 2,200 2,200 2,200 2,000 2,200
Insulation Resistance
Initially @ 500 Vdc megohms 100 100 100 100 100 100 100 100 100 100 100 100 100
At End of Life @ 500 Vdc megohms 50 50 50 50 50 50 50 50 50 50 50 50 50
Environmental Data
Operating Temperature Range °C -55 to +85 -55 to +85 -55 to +85 -55 to +85 -55 to +85 -55 to +85 -55 to +85 -40 to +85 -40 to +60 -40 to +85 -40 to +85 -40 to +85 -40 to +85
Storage Temperature Range °C -65 to +125 -65 to +125 -65 to +125 -65 to +125 -65 to +125 -65 to +125 -65 to +125 -65 to +125 -65 to +125 -65 to +125 -65 to +125 -65 to +125 -65 to +125
Shock, 11ms, 1/2 Sine G’s 20 20 20 20 30 20 20 20 30 (Closed)/ 30 20 20 20
10 (Open)
Vibration, Sine (55-2,000 Hz) G’s 20 20 20 20 20 20 20 20 10 20 20 20 20
Coil Transient Suppression No X, Yes/Latch, No Yes Yes Yes Yes Yes Yes Yes No Yes No No
Mechanical Data
Operate Time @ 25°C ms 40/20 40/20 40/20 40/20 40/20 40/20 25/15 25/15 25/15 25/15 25/15 25/15 25
(Including Bounce), Max./Typ.
Release Time, Max. ms 15 15 15 15 15 15 10 12 15 15 15 10 15
Bounce Time, Max. ms 5 5 5 5 5 5 5 7 5 5 5 5 5
Mechanical Life, Min. Cycles 100,000 100,000 100,000 100,000 100,000 100,000 100,000 1,000,000 100,000 100,000 1,000,000 1,000,000 100,000
Weight (Nominal) lb. (kg) 0.79 (.35) 0.79 (.35) 0.95 (.43) 0.95 (.43) 1.3 (.59) 0.95 (.43) 6.70 (190) 0.95 (.43) 0.95 (.43) .99 (.53) .28 (.130) 0.42 (.19) 1.3 (.60)
Coil Voltage (Nominal) Vdc 28 28 28 28 28 28 28 9-36 12/24 12/24 9-36 12/24/48 12/24/48
Note: Consult TE Connectivity for complete specifications, detailed performance characteristics and additional models.
KILOVAC High Voltage
DC Contactors
7
PAGE 5
KILOVAC High Voltage DC Contactors
KILOVAC High Voltage DC Contactors Quick Reference Guide (Continued)
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
(MAP) (CAP) (EV) (LEV)
Aerospace Military Aerospace Commercial OEM/Commercial &Electric Vehicle Industrial Commercial
Product Series MAP101 MAP100 MAP200 MAP201 CAP202 CAP200 CAP100 EV200A EV200B EV200P EV100 LEV100 LEV200
Main Contact Data
Continuous Current A 100 100 500 350 300 500 100 500 500 500 100 100 500
Contact Voltage Range Vdc 12-900 12-900 12-900 12-900 12-900 12-900 12-900 12-900 12-900 12-900 12-900 900 12-900
Electrical Life at Rated Current, Cycles 25,000 15,000 1,000 5,000 10,000 1,000 6,000 1,000 500 500 6,000 6,000 1,000
270 Vdc, Resistive Load
Overload (Make/Break) @ 350 Vdc A 2,000/2,000 500/1,500 650/2,000 2,000/2,000 650/2,000 650/2,000 600/1000 650/2000 650/1000 650/1000 600/1000 600/1000 650/2000
Rupture (Break only) @ 350 Vdc A 2,000 1,500 2,000 2,000 2,000 2,000 1000 2000 1000 1000 1000 1000 1000
Contact Arrangement SPST SPST SPST SPST DPST SPST SPST SPST SPST SPST SPST SPST SPST
Contact Form Latch X (NO) X (NO) X (NO) 2X (NO) X (NO) X (NO) X(NO) Y(NC) X (LATCH) X(NO) X(NO) X(NO)
or Latch
Contact Resistance @ Rated Current milliohms 0.75 0.5 0.2 0.3 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2
Auxiliary Contact Data
Contact Form/Quantity of Sets (Max.) Form A/1 Form A/1 Form A/1 Form A/1 Form C/4 Form A/2 Form C/1 Form A/1 Form A/1 Form A/1 None Form X/1 Form X/1
Current Rating @ 30 Vdc (Ag/Au), Max. A 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1 2.0/0.1
Minimum Signal Level Vdc/mAdc Ag 6V/15mA Ag 6V/15mA Ag 6V/15mA Ag 6V/15mA Ag 6V/15mA Ag 6V/15mA Ag 6V/15mA Ag 6V/15mA Ag 6V/15mA Ag 6V/15mA — — Ag 6V/15mA
Au 5V/5mA Au 5V/5mA Au 5V/5mA Au 5V/5mA Au 5V/5mA Au 5V/5mA Au 5V/5mA Au 5V/5mA Au 5V/5mA Au 5V/5mA Au 5V/5mA
Dielectric Withstanding Voltage
Contacts to Coil to All Other Points Vrms 1,500 1,500 2,200 2,200 2,200 2,200 2,200 2,200 2,200 2,200 2,200 2,000 2,200
Insulation Resistance
Initially @ 500 Vdc megohms 100 100 100 100 100 100 100 100 100 100 100 100 100
At End of Life @ 500 Vdc megohms 50 50 50 50 50 50 50 50 50 50 50 50 50
Environmental Data
Operating Temperature Range °C -55 to +85 -55 to +85 -55 to +85 -55 to +85 -55 to +85 -55 to +85 -55 to +85 -40 to +85 -40 to +60 -40 to +85 -40 to +85 -40 to +85 -40 to +85
Storage Temperature Range °C -65 to +125 -65 to +125 -65 to +125 -65 to +125 -65 to +125 -65 to +125 -65 to +125 -65 to +125 -65 to +125 -65 to +125 -65 to +125 -65 to +125 -65 to +125
Shock, 11ms, 1/2 Sine G’s 20 20 20 20 30 20 20 20 30 (Closed)/ 30 20 20 20
10 (Open)
Vibration, Sine (55-2,000 Hz) G’s 20 20 20 20 20 20 20 20 10 20 20 20 20
Coil Transient Suppression No X, Yes/Latch, No Yes Yes Yes Yes Yes Yes Yes No Yes No No
Mechanical Data
Operate Time @ 25°C ms 40/20 40/20 40/20 40/20 40/20 40/20 25/15 25/15 25/15 25/15 25/15 25/15 25
(Including Bounce), Max./Typ.
Release Time, Max. ms 15 15 15 15 15 15 10 12 15 15 15 10 15
Bounce Time, Max. ms 5 5 5 5 5 5 5 7 5 5 5 5 5
Mechanical Life, Min. Cycles 100,000 100,000 100,000 100,000 100,000 100,000 100,000 1,000,000 100,000 100,000 1,000,000 1,000,000 100,000
Weight (Nominal) lb. (kg) 0.79 (.35) 0.79 (.35) 0.95 (.43) 0.95 (.43) 1.3 (.59) 0.95 (.43) 6.70 (190) 0.95 (.43) 0.95 (.43) .99 (.53) .28 (.130) 0.42 (.19) 1.3 (.60)
Coil Voltage (Nominal) Vdc 28 28 28 28 28 28 28 9-36 12/24 12/24 9-36 12/24/48 12/24/48
Note: Consult TE Connectivity for complete specifications, detailed performance characteristics and additional models.
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
Ordering Information
Typical Part Number MAP101 R B A F E
Series:
MAP101 = 100 Amp, 12-900VDC Contactor
Dual Contact Material
Contact Form:
R - Latch with 1 SPST NO Aux.
Coil Voltage:
B = 28 Vdc Coil
Lead Length:
A = 15.3 in. (300 mm)
Coil Terminal Connector:
N = None
F = Plug on Flying Lead, 9 Pin Micro-D
Mounting & Power Terminals
E = side mount with 2x#8
10-32 Female Power Terminals
KILOVAC MAP101 Series Contactor with 1 Form A (SPST-NO) Contacts
Rated up to 100 Amps, 12-900 Vdc Dual Contact Material (Cu/Mo)
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
Physical Data
Contact Arrangement —
Main Contacts —
SPST-Latching (form X)
1X Auxiliary Contact —
SPST-NO (form A)
Dimensions — See drawing
Weight, Nominal —
0.35 Kg (12.35 oz)
Environmental Data
Shock, 11ms 1/2 Sine
(Operating) — 20 Gpeak
Sine Vibration, 20 Gpeak —
55-2000 Hz
Random Vibration, 14.06 Grms —
15 Hz (.002 G2/Hz), 100 Hz (.002 G2/Hz),
450 Hz (.12 G2/Hz), 900 Hz (.12 G2/Hz),
2000 Hz (.083 G2/Hz)
Operating Temperature Range —
-55°C to +85°C
Electrical Data
Voltage Rating —
Main Contacts (max) — 400 Vdc
Auxiliary Contacts — 30 Vdc
Current Rating, Continuous —
Main Contacts 1 — 100 A
Auxiliary Contacts — 3 A
Contact Resistance —
Main Contacts —
100 mΩ max @ 1 amp
0.75 mΩ max @ rated current
Auxiliary Contacts —
200 mΩ max
Electric Life at Rated Current 270
Vdc, Resistive Load —
25,000 cycles
Mechanical Life — 1 million cycles
Dielectric Withstand Voltage —
Terminal to Terminal/ Terminals to Coil
— 1mA max @ 1,300Vrms
Insulation Resistance —
Terminal to Terminal/ Terminals to Coil
—
100MΩ min @ 500Vdc new
50MΩ min @ 500Vdc end of life
Note:
1 Continuous current rating is
affected by conductors attached.
Keep terminals below 150°C max
continuous.
Coil Data
Coil Voltage, Nominal/ Max —
28/ 32 Vdc
Coil Resistance @ 25°C —
Contacts Close Coil — 18 Ω
Contacts Open Coil — 13 Ω
Pick Up/ Drop Out (Max) —
16 Vdc (-55°C to +25°C)
18 Vdc (+25°C to +85°C)
Coil Current (Max) @ 32Vdc/
-40°C — 4.0 A
Coil Current On Time (Minimum
Required to Latch) — 40 ms
Main Contacts —
Operate Time (Max) — 40 ms
Operate Bounce (Max) — 5 ms
Release Time — 25 ms
Auxiliary Contacts Operate/
Release — Within ± 5 ms of main
Product Facts
n Dual contact material
(copper/moly) designed
for high current make
and interrupt military
aerospace, ground vehicle
and naval applications
n Hermetically sealed,
intrinsically safe, operates
in explosive/harsh
environments with no
oxidation or contamination
of coils or contacts, during
long periods of non-
operation
n Comes standard with 1
SPST-NO Aux. contact
n Not position sensitive,
can be mounted in any
orientation
n RoHS versions available
KILOVAC High Voltage
DC Contactors
7
PAGE 7
KILOVAC High Voltage DC Contactors
KILOVAC MAP101 Series Contactor (Continued)
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
Outline Dimensions
Connector Pin-Out
1 Not Connected
2 Aux. NO
3 Close Return
4 Close Return
5 +28Vdc
6 Aux. Com.
7 Open Return
8 Open Return
9 +28V
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC MAP100 Series Contactor with 1 Form A (SPST-NO)
Contacts Rated up to 100 Amps, 12-900 Vdc
Physical Data
Contact Arrangement —
Main Contacts —
SPST-Latching (or NO Form X)
1X Auxiliary Contact —
SPST-NO (form A)
Dimensions — See drawing
Weight, Nominal —
0.35 Kg (12.35 oz)
Environmental Data
Shock, 11ms 1/2 Sine
(Operating) — 20 Gpeak
Sine Vibration, 20 Gpeak —
55-2000 Hz
Random Vibration, 14.06 Grms —
15 Hz (.002 G2/Hz), 100 Hz (.002 G2/Hz),
450 Hz (.12 G2/Hz), 900 Hz (.12 G2/Hz),
2000 Hz (.083 G2/Hz)
Operating Temperature Range —
-55°C to +85°C
Electrical Data
Voltage Rating —
Main Contacts (max) — 400 Vdc
Auxiliary Contacts — 30 Vdc
Current Rating, Continuous —
Main Contacts 1 — 100 A
Auxiliary Contacts — 3 A
Contact Resistance —
Main Contacts —
100 mΩ max @ 1 amp
0.75 mΩ max @ rated current
Auxiliary Contacts —
200 mΩ max
Electrical Life at Rated Current,
270 Vdc, Resistive Load —
15,000 cycles
Mechanical Life — 1 million cycles
Dielectric Withstand Voltage —
Terminal to Terminal/ Terminals to Coil
— 1mA max @ 1,300Vrms
Insulation Resistance —
Terminal to Terminal/ Terminals to Coil
—
100MΩ min @ 500Vdc new
50MΩ min @ 500Vdc end of life
Note:
1 Continuous current rating is
affected by conductors attached.
Keep terminals below 150°C max
continuous.
Coil Data
Coil Voltage, Nominal/ Max —
28/ 32 Vdc
Coil Resistance @ 25°C —
Contacts Close Coil — 18 Ω
Contacts Open Coil — 13 Ω
Pick Up/ Drop Out (Max) —
16 Vdc (-55°C to +25°C)
18 Vdc (+25°C to +85°C)
Coil Current (Max) @ 32Vdc/
-40°C — 4.0 A
Coil Current On Time (Minimum
Required to Latch) — 40 ms
Main Contacts —
Operate Time (Max) — 40 ms
Operate Bounce (Max) — 5 ms
Release Time — 25 ms
Auxiliary Contacts Operate/
Release — Within ± 5 ms of main
Product Facts
n Solid copper contacts
designed for high current
carry military aerospace,
ground vehicle and naval
applications
n Hermetically sealed,
intrinsically safe,
operates in explosive/
harsh environments with
no contact oxidation or
contamination of coil
or contacts, during long
periods of non- operation
n Comes standard with 1
SPST-NO Aux. contact
n Not position sensitive,
can be mounted in any
orientation
n RoHS versions available
Ordering Information
Typical Part Number MAP100 R B A F E
Series:
MAP100 = 100 Amp, 12-900VDC Contactor
Contact Form:
H = NO with 1 SPST NO Aux.
R - Latch with 1 SPST NO Aux.
Coil Voltage:
B = 28 Vdc Coil
Lead Length:
A = 15.3 in. (300 mm)
Coil Terminal Connector:
N = None
F = Plug on Flying Lead, 9 Pin Micro-D
Mounting & Power Terminals
E = side mount with 2x#8
10-32 Female Power Terminals
KILOVAC High Voltage
DC Contactors
7
PAGE 9
KILOVAC High Voltage DC Contactors
KILOVAC MAP100 Series Contactor (Continued)
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
Outline Dimensions
Connector Pin-Out
1 Not Connected
2 Aux. NO
3 Close Return
4 Close Return
5 +28Vdc
6 Aux. Com.
7 Open Return
8 Open Return
9 +28V
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC MAP200 Series Contactor with 1 Form A (SPST-NO)
Contacts Rated up to 500 Amps, 12-900 Vdc
Performance Data
Contact Arrangement, Power
Contacts — 1 Form A (SPST-NO)
Rated Operating Voltage —
12 - 900 VDC
Continuous (Carry) Current,
Typical — 500 A @ 85°C, 400 mcm
conductors
Consult Factory for required con-
ductors for higher currents
Make/Break Current at Various
Voltages 1 — See graph next page
Break Current at 320VDC 1 —
2,000 A, 1 cycle
Contact Resistance, Typ.
(@200A) — 0.2 mohms
Load Life — See graph next page
Mechanical Life — 1 million cycles
Contact Arrangement, Auxiliary
Contacts — 1 Form A (SPST-NO)
Aux. Contact Current, Max. —
2A @ 30VDC / 3A @ 125VAC
Aux. Contact Current, Min. —
100mA @ 8V
Aux. Contact Resistance, Max. —
0.417 ohms @ 30VDC /
.150 ohms @ 125VAC
Dielectric Withstanding Voltage —
2,200 Vrms @ sea level
Insulation Resistance @ 500VDC —
100 megohms 2
Shock, 11ms 1/2 Sine, Peak,
Operating — 20 G
Vibration, Sine, 50-2000Hz.,
Peak — 20 G
Operating Temperature —
-55°C to +85°C
Weight, Nominal — .95 lb. (.43 kg)
Notes:
1 Main power contacts
2 50 at end of life
Coil Operating Voltage (Valid Over Temperature Range)
Voltage (Will Operate) 18-32VDC
Voltage (Max.) 32VDC
Pickup (Close) Voltage Max. 18VDC
Hold Voltage (Min.) 10VDC
Dropout (Open) Voltage (Min.) 2VDC
Inrush Current (Max.) 4.5A
Holding Current (Avg.) 0.5A
Inrush Time (Max.) 100ms
Product Facts
n Designed to be the
smallest, lightest weight,
lowest cost sealed contactor
in the industry with its
current rating for military
aerospace, ground vehicle
and naval, high current
applications
n Built-in coil economizer
(models requiring external
economizer also available)
n Optional auxiliary contact
for easy monitoring of
power contact position
n Hermetically sealed
— intrinsically safe,
operates in explosive/
harsh environments with no
oxidation or contamination
of coil or contacts,
including long periods of
non-operation
n Versatile coil and power
connections
n RoHS versions available
Ordering Information
Typical Part Number MAP200 A R D E A
Series:
MAP200 = 500 Amp, 12-900VDC Contactor
Contact Form:
A = Normally Open
H = Normally Open with Aux. Contacts
Coil Voltage:
R = 28 Vdc, Mechanical Economizer
S = 28 Vdc, Electrical Cut-throat Economizer
Coil Wire Length:
A = 15.3 in (390 mm)
D = Coil connector on relay (requires option “E” or
“X” in next step).
Coil Terminal Connector:
N = No connector
E = 9-pin subminiature “D” plug mounted on contactor
housing
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
D = Bottom Mount & Female M6 x 1 Thread Terminals
KILOVAC High Voltage
DC Contactors
7
PAGE 11
KILOVAC High Voltage DC Contactors
KILOVAC MAP200 Series (Continued)
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
Outline Dimensions
1.65 ± .01
(42.0 ± .26)
2.688 ± .01
(68.28 ± .26)
1.05 ± .01
(26.67 ± .26)
LABEL
2 X 10-32 THREAD THRU
TORQUE: 15 TO 30 IN-LB (1.7 TO 3.3 NM)
2 X M6 x 1 THREAD
.45 (11.43) MIN DEPTH (11 THREADS)
TORQUE VS THREAD ENGAGEMENT
8 TO 11 THREADS: 80 TO 100 IN-LB (9.1 TO 11.3 NM)
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)
.800 ± .01
(20.3 ± .26)
3.289 ± .025
(83.54
± .635)
3.17 ± .01
(80.48 ± .26)
2.20 ± .025
(55.81 ± .63)
2.523 ± .025
(64.08 ± .635)
2.245 ± .025
(57.02 ± .635)
1.431 ± .025
(36.35 ± .635)
.546 ± .01
(13.87 ± .26)
WIRE VIEW REMOVED
FOR CLARITY
Estimated Make & Break Power Switching Ratings
NOTES:
1) For resistive loads with 300µH 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.
100,000
10,000
1,000
100
10
11,000 10,000
100101
Make and Break Power Switching Region Break Only Above 650A
650A
Estimated Life (Cycles)
Load Current (A)
1800 VDC
900 VDC
600 VDC
400 VDC
270 VDC
120 VDC
28 VDC
MAP200HR D-Sub
Pin Out
Coil+ = Pin 2
Coil - = Pin 6
Aux. COM = Pin 8
Aux. NO = Pin 4
MAP200AR
Coil+ = Pin 2
Coil - = Pin 6
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC MAP201 Series Contactor with 2 Form A (SPST-NO)
Contacts Rated up to 350 Amps, 12-900 Vdc Dual Contact Material (Cu/Mo)
Physical Data
Contact Arrangement —
Power Contacts —
SPST-NO (form X)
2X Auxiliary Contacts 1 —
SPST-NO (form A)
Dimensions — See drawing
Weight, Nominal — 0.45 Kg (0.99 lb)
Environmental Data
Shock, 11ms 1/2 Sine
(Operating) — 20 Gpeak
Sine Vibration, 20 Gpeak —
55-2000 Hz
Random Vibration, 14.06 Grms —
15 Hz (.002 G2/Hz), 100 Hz (.002 G2/Hz),
450 Hz (.12 G2/Hz), 900 Hz (.12 G2/Hz),
2000 Hz (.083 G2/Hz)
Operating Temperature Range —
-55°C to +85°C
Electrical Data
Voltage Rating —
Main Contacts (max) — 400 Vdc
Auxiliary Contacts — 30 Vdc
Current Rating, Continuous —
Main Contacts 2 — 300 A
Auxiliary Contacts — 3 A
Contact Resistance —
Main Contacts 3 —
100 mΩ max @ 1 amp
0.3 mΩ max @ rated current
Auxiliary Contacts —
200 mΩ max
Hot Switching Performance
(Polarity Sensitive) —
600A make/ 265A break @ ± 270Vdc —
11,000 cycles
550A make/ break @ ± 360Vdc —
100 cycles
2000A capacitive make — 100 cycles
2000A make/ break @ +360Vdc —
5 cycles
1000A make/ break @ -360Vdc —
2 cycles
Mechanical Life — 1 million cycles
Dielectric Withstand Voltage —
Terminal to Terminal/ Terminals to Coil
— 1mA max @ 2,200Vrms
Insulation Resistance —
Terminal to Terminal/ Terminals to Coil
—
100MΩ min @ 500Vdc
Notes:
1 Two form A available with elec-
tronic coil economizer, 1 form A
available with mechanical coil
economizer
2 Continuous current rating is
affected by conductors attached.
Keep terminals below 150°C max
continuous, 175C for 1 hour max,
and 200C for 1 minute max.
3 Initial contact resistance may be
higher than 0.3mΩ, but will drop
below within 30 minutes maximum
Coil Data
Coil Voltage, Nominal/ Max —
28/ 32 Vdc
Pick Up (Max) — 16 Vdc
Inrush Current @ 28Vdc (Max) —
3.5 A
Inrush Time (Max) — 100 ms
Hold Current (Max) — 0.32 A
Drop Out — 4 to 10 Vdc
Main Contacts —
Operate Time (Max) — 18 ms
Operate Bounce (Max) — 5 ms
Release Time — 18 ms
Auxiliary Contacts Operate/
Release — Within ± 5 ms of main
Product Facts
n Designed to be the
smallest, lightest weight,
lowest cost sealed contactor
in the industry with its
current rating for military
aerospace
n Built-in coil economizer
(models requiring external
economizer also available)
n Optional auxiliary contact
for easy monitoring of
power contact position
n Hermetically sealed
— intrinsically safe,
operates in explosive/
harsh environments with no
oxidation or contamination
of coil or contacts,
including long periods of
non-operation
n Versatile coil and power
connections
n RoHS versions available
Ordering Information
Typical Part Number MAP201 A R D E A
Series:
MAP201 = 350 Amp, 12-900VDC Contactor
Contact Form:
A = Normally Open
H = Normally Open with Aux. Contacts
Coil Voltage:
R = 28 Vdc, Mechanical Economizer
S = 28 Vdc, Electrical Cut-throat Economizer
Coil Wire Length:
A = 15.3 in (390 mm)
D = Coil connector on relay (requires option “E” or
“X” in next step).
Coil Terminal Connector:
N = No connector
E = 9-pin subminiature “D” plug mounted on contactor
housing
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
D = Bottom Mount & Female M6 x 1 Thread Terminals
KILOVAC High Voltage
DC Contactors
7
PAGE 13
KILOVAC High Voltage DC Contactors
KILOVAC MAP201 Series Contactor (Continued)
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
Outline Dimensions*
Flying Lead “D”
Connector Pin-Out
1 N/C
2 AUX1 COM
3 AUX2 COM
4 RTN1
5 +28Vdc
6 N/C
7 AUX3 NO
8 AUX2 NO
9 RTN2
* Alternate coil and main
terminal connections
available, consult factory.
MAP200HR D-Sub
Pin Out
Coil+ = Pin 2
Coil - = Pin 6
Aux. COM = Pin 8
Aux. NO = Pin 4
MAP200AR
Coil+ = Pin 2
Coil - = Pin 6
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC CAP202 Series Aerospace Commercial Contactor with 2 Form X
(DPST-NO), Contacts Rated up to 300 Amps, 12-600 Vdc
Product Facts
n Hermetically sealed
n Up to 4X SPDT auxiliary
switch outputs: 30 Vdc/2A
max switching or 6V/5mA
min. signal
n Integrated coil economizer
with coil suppression
n EMC compliant - no radiated
coil emission
n Bidirectional switching -
main contacts not polarity
sensitive
n Mount in any orientation
-not position sensitive
Description
2-pole single throw hermet-
ically sealed DC contactor;
12-900 Vdc/350A per pole
Not position sensitive
Bi-directional switching
Applications
High Voltage DC Converter
Systems (ref schematic
below)
Test Equipment
Power Distribution
Power Motion Control
Electrical
Compact epoxy-sealed resin
enclosure occupies only
about 4 in3 (65.5 cm3)
Contact arrangement:
DPST-No (2 form X)
Voltage rating: 12-900 Vdc
(main contacts); 30 Vdc
(auxiliary)
Mechanical life: 100,000
cycles
Physical or Other Properties
Weight: 0.79 Kg
Hermetically sealed
Safe for harsh/corrosive
environments
No contacts oxidation over
periods on non-use
Number of SPDT Auxiliary
Contacts per Contactor Type:
CAP202AS — None
CAP202MS — Two
CAP202FS — Four
Performance Data
Physical Data
Contact Arrangement —
Power Contacts — DPST-NO (2 Form X)
Auxiliary Switches — SPDT (form C)
Dimensions — See drawings on next
page
Weight — 0.79 Kg (1.74 lb.)
Electrical Data
Voltage Rating —
Main Contacts — 12-900Vdc
Auxiliary Catacts — 30VdC
Current Rating —
Main Contacts1 — 350A/pole
Auxiliary Catacts — 3A
Contact Resistance —
Main Contacts — (2)
100 mΩ max @ 1 amp
0.3 mΩ max. @ 200A after 3 mins.
Auxiliary Catacts — 200 mΩ max
Hot Switching Performance @
± 400 Vdc (3) —
100A make/break — 10,000 cycles
250A make/break — 2,500 cycles
700A break only — 10 cycles
Hot Switching Performance @
± 270 Vdc (4) —
100A make/break — 40,000 cycles
250A make/break — 7,500 cycles
2000A break only @ ±370Vdc (5) —
2 cycles
Maximum Make Current — 700A
Dielectric Withstand Voltage over
Life — Terminal to Terminal/Terminals
to Coil — 1mA max @ 2,200Vrms
Insulation Resistance over Life
— Terminal to Terminal/Terminals to
Coil — 50mΩ min @ 500Vdc
Mechanical Life — 100,000 cycles
Environmental Data
Shock, 11ms 1/2 sine (operating)
— 20G peak
Sine Vibration, 10G peak —
55-2,000 Hz.
Random Vibration, 14 Grms —
15 100 300 900 2000 Hz
.01 .01 .2 .2 .01 G2/Hz
Operating Temperature Range —
-55°C to +85°C
Notes:
1 Using 4/0 conductor. Current rating
is affected by attached conductor
size and design. Keep terminals
below 150˚C max. continuous,
175˚C for 2 hours max. and 200˚C
for 1 minute max. For mounting
large conductors, request terminal
adapter PN 3-1618396-7.
2 Operational contact resistance is
measured by millivolt drop across
contacts a > 100A current. Initial
contact resistance may be higher
than 0.3mΩ, but will drop below
within 30 mins. max.
3 Voltage applied to each contact set
separately.
4 Voltage applied across both con-
tact sets in series.
5 May not pass 2,200 Vrms dielectric
testing after second interrupt cycle.
+
+
DPST-NO
CAP202 Contactor
270Vdc
Supply
270Vdc
Supply
270Vdc
Return
270Vdc
Components
270Vdc
Components
540Vdc
Components
KILOVAC High Voltage
DC Contactors
7
PAGE 15
KILOVAC High Voltage DC Contactors
KILOVAC CAP202 Series 12-900Vdc Contactors
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
Ordering Information
Typical Part Number CAP202 M S B F D
Series:
CAP202 = 2 form X, DPST-N0-DM Contactor
Auxiliary Contact Outputs (SPDT form C):
A = None
M = Two
F = Four
Coil Voltage:
S = 28V (with built-in electronically switched dual
coil economizer)
Coil and Aux. Wire Length:
A = 15.3 inches
B = 6 inches
X = Customer Special
Coil and Aux. Connector:
N = None
F = D Plug on flying leads (may affect wire length)
Mounting & Power Terminals:
D = 2X M5 Bottom Mount with 4X, M6 x 1 Female thread
terminals
Specifications are subject to change without notice.
Coil Data (-40 to +85˚C temp range unless otherwise noted)
Voltage/Nominal Max. 28-32VDC
Pickup Voltage Max. 16VDC
Inrush Current @ 28 Vdc nominal/@32V maximum 3.4/6.0A
Inrush Time (nominal/maximum) 75/150mS
Hold Current @28V nominal / @32V maximum 0.27/0.48A
Drop Out Voltage 3 to 8Vdc
Internal Coil Suppression (max.) 60Vdc
Main Contacts: Operate Time, nominal/maximum 13/20mS
Main Contacts: Operate Bounce, nominal/maximum 3/10mS
Main Contacts: Release Time, nominal/maximum 25mS
Main Contacts: Release Time, maximum including
Maximum arc time 7/12mS
Outline Dimensions*
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC CAP200 Series Contactor with 1 Form A (SPST-NO)
Contacts Rated up to 500 Amps, 12-900 Vdc
Performance Data
Contact Arrangement, Power
Contacts — 1 Form A (SPST-NO)
Rated Operating Voltage —
12 - 900 VDC
Continuous (Carry) Current,
Typical — 500 A @ 85°C, 400 mcm
conductors
Consult Factory for required con-
ductors for higher currents
Make/Break Current at Various
Voltages 1 — See graph next page
Break Current at 320VDC 1 —
2,000 A, 1 cycle 3
Contact Resistance, Typ.
(@200A) — 0.2 mohms
Load Life — See graph next page
Mechanical Life — 1 million cycles
Contact Arrangement, Auxiliary
Contacts — 1 Form A (SPST-NO)
Aux. Contact Current, Max. —
2A @ 30VDC / 3A @ 125VAC
Aux. Contact Current, Min. —
100mA @ 8V
Aux. Contact Resistance, Max. —
0.417 ohms @ 30VDC /
.150 ohms @ 125VAC
Dielectric Withstanding Voltage —
2,200 Vrms @ sea level
Insulation Resistance @ 500VDC —
100 megohms 2
Shock, 11ms 1/2 Sine, Peak,
Operating — 20 G
Vibration, Sine, 80-2000Hz.,
Peak — 20 G
Operating Temperature —
-40°C to +85°C
Weight, Nominal — .95 lb. (.43 kg)
Notes:
1 Main power contacts
2 50 at end of life
3 Does not meet dielectric & IR after
test, 1700 amp for unit with Aux.
Contacts
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
Product Facts
n Designed to be the
smallest, lightest weight,
lowest cost sealed contactor
in the industry with its
current rating
n Built-in coil economizer
— only 1.7W hold power
@ 12VDC and it limits
back EMF to 0V. (models
requiring external
economizer also available)
n Optional auxiliary contact
for easy monitoring of
power contact position
n Hermetically sealed
— intrinsically safe,
operates in explosive/
harsh environments with no
oxidation or contamination
of coil or contacts,
including long periods of
non-operation
n Versatile coil and power
connections
n RoHS versions available
Ordering Information
Typical Part Number CAP200 A A A N A
Series:
CAP200 = 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 = 28 Vdc with mechanical economizer
Coil Wire Length:
A = 15.3 in (390 mm)
D = Coil connector on relay (requires option
“E” or “X” in next step)
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.
X = Special configuration (consult factory)
Mounting & Power Terminals:
A = Bottom Mount & Male 10mm x 8 Terminals
KILOVAC High Voltage
DC Contactors
7
PAGE 17
KILOVAC High Voltage DC Contactors
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC CAP200 Series (Continued)
Outline Dimensions
AUXILIARY CONTACT LEADS
COIL LEADS
WHITE = AUXILIARY CONTACT
(WHEN ORDERED)
BLACK = – COIL
RED = + COIL
SEE COIL WIRE
LENGTH IN P/N
STAINLESS 2.85 ± .025
(72.3 ± .63)
.5 ± .01
(12.6 ± .26)
2.05 ± .02
(52 ± .51)
2.58 ± .02
(65.6 ± .51)
.55 ± .025
(14.04 ± .63)
2.20 ± .025
(55.81 ± .63)
2.04 ± .02 DIA
(51.94 ± .51)
3.17 ± .01
(80.48 ± .26)
2.29 ± .02 DIA
(58.19 ± .51)
1.05 ± .01
(26.67 ± .26)
1.65 ± .01
(42.0 ± .26)
2.688 ± .01
(68.28 ± .26)
A1
"+" POSITIVE TERMINAL
A2 "–" NEGATIVE TERMINAL
.225 ± .01DIA
(5.72 ± .26)
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)
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)
Estimated Make & Break Power Switching Ratings
NOTES:
1) For resistive loads with 300µH 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.
100,000
10,000
1,000
100
10
11,000 10,000
100101
Make and Break Power Switching Region Break Only Above 650A
650A
Estimated Life (Cycles)
Load Current (A)
1800 VDC
900 VDC
600 VDC
400 VDC
270 VDC
120 VDC
28 VDC
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC CAP120 Series 900 Vdc Contactor
Product Facts
n Suitable for application
in harsh and explosive
environments
n No contact oxidation over
periods of non-use
n Size reduced version
of MAP/CAP 100 Series
contactors
n Bidirectional switching
n Main contacts not polarity
sensitive
n Panel mount
n Not position sensitive:
mounts in any orientation
n Integrated dual-coil
electronic “cut-throat”
economizer with suppression
Applications
n Energy storage systems
n Power distribution
n High-current battery systems
n Lithium ion battery systems
n Solar power
Description
Designed for harsh environ-
ments and loads, the new
KILOVAC CAP120 contac-
tor from TE Connectivity
(TE) offers exceptional per-
formance for a device this
small and light. A reduced-
size version of our popular
MAP and CAP series
contactors, the CAP120
contactor’s small size and
light weight opens up new
application possibilities for a
150 A/600 Vdc device.
High break levels—1000 A
at 400 Vdc and 600 A at 600
Vdc—help increase system
flexibility and reliability.
CAP120 contactors provide
reliable and long-lasting
performance in military
ground, military and
commercial aerospace, and
marine applications.
Performance Data
Electrical Data
Contact Arrangement — SPST-NO
(form X)
Voltage Rating — 600 Vdc
Current Rating — 150 A continuous
Contact Resistance — 0.6 mΩ
Contact Voltage Drop @ 150 A —
80 mV max.
Hot-Switching Performance,
Resistive Load @ 600 Vdc —
100 A Make/Break — 1000 cycles
600 A Break — 5 cycles
600 A Make — 25 cycles
Hot-Switching Performance,
Resistive Load @ 400 Vdc —
150 A Make/Break — 3250 cycles
1000 A Break Only — 5 cycles
Maximum Pulse Through Closed
Contacts — 1250 A
Dielectric Withstanding Voltage
over Life —
Terminal to Terminal — 1 mA max.
@2800 Vrms
Terminals to Coil — 1 mA max. @1500
Vrms
Insulation Resistance over Life —
Terminal to Terminal — 100 MΩ @
500 Vdc new
Terminals to Coil — 50 MΩ min. @
500 Vdc end of life
Mechanical Life — 100,000 cycles
min.
Mechanical Data
Shock — 11ms 1/2 sine (operating):
20 g peak
Sine Vibration — 25 g peak: 55 to
2000 Hz
Random Vibration — 13.3 grms:
Operating Temperature Range —
40°C to +85°C
Weight — 0.14 kg
Sealing — Hermetic
Schematic
+
_
A2 A1
RED
BLK
Coil
+
Integrated
Economizer
with Suppression
Coil Wire:
22 AWG
M22759/11
KILOVAC High Voltage
DC Contactors
7
PAGE 19
KILOVAC High Voltage DC Contactors
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC CAP120 Series (Continued)
1.78
1.50
2.12
1.82
0.70
0.32
COIL WIRES
22 AWG (M22759/11)
15 INCH LENGTH
MOUNTING HARWARE
(NOT SUPPLIED)
M4 BOLT, LOCKWASHER, AND NUT
LOAD TERMINALS
(NOT SUPPLIED)
M5 BOLT, LOCKWASHER, AND NUT
A1 A2
Coil Voltage Description Part No.
28 Vdc CAP120ASANG 2-1618403-6
12 Vdc CAP120AVANG 2-1618411-9
28 Vdc 12 Vdc
Coil Voltage, nom.: 28 Vdc 12 Vdc
Pick Up Voltage, max. over temperature range: 16 Vdc 8.5 Vdc
Hold Voltage, min: 12 Vdc 7 Vdc
Dropout Voltage: 6 Vdc min. 7 Vdc max.
Pickup Coil Resistance: 6.5 Ω2.5 Ω
Hold Coil Resistance: 200 Ω 51 Ω
Coil Inrush Current @ 28 Vdc nom.: 4.5 A 4.5 A
Hold Current @28 Vdc 0.15 A 0.25 A
Coil Inrush Time, max.: 100 ms 100 ms
Operate Time: 8 ms 15 ms
Operate Bounce: 3 ms 5 ms
Release Time: 5 ms 5 ms
Coil Suppression (max.) 42 V 42 V
Coil Operating Voltage (Valid Over Temperature Range)
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
KILOVAC KHR500 High-Voltage 600 Amp Contactors
Product Facts
n 600 A carry
n 3300 A break at 400 Vdc
n 4000 A make current
n Bidirectional load switching
n Safe for application in harsh
and explosive environments
n Not position sensitive
n Rugged, robust design
n Smaller and up to 64%
lighter than our popular
EV500 BUBBA contactors
n Integrated dual-coil
electronic “cut throat”
economizer
n Switches voltages from 28
to 1000 Vdc
Applications
n Aerospace
n Ground vehicles
n Marine
n Solar
n Automotive
n Energy storage systems
n UL 508 recognized for US
and Canada
Description
TE Connectivity’s (TE)
KILOVAC KHR500 “BUBBA
II” feature smaller size and
lighter weight than our
popular EV500 “BUBBA”
high-voltage contactors.
Capable of handling inrush
currents as high 4000 A, the
contactors are hermetically
sealed for use in hazardous
or explosive environments.
Configured as a single-pole,
single-throw device, the
contactors can handle
voltages from 28 to 1000
Vdc and continuous 600 A
currents.
Because it is not polarity
sensitive, the contactor
allows bidirectional load
switching. An integrated coil
economizer reduces the
power required to hold the
contacts closed to 320 mA
at 24 Vdc.
A single-pole, double-throw
auxiliary switch supports 3
A @ 125 Vrms or 1 A @ 30
Vdc, and low-level signals
down to 5 V/10 mA.
Electrical Data
Main Contact Arrangement —
SPST (1 Form X)
Auxiliary Contact Arrangement —
SPDT (1 For C)
Voltage Rating:
Main Contact — 28 to 1000 Vdc
Auxiliary Contacts — (3 A @ 125
Vrms or 1 A @ 30 Vdc)
Current Rating:
Main Contacts, Continuous —
600 A
Contact Resistance:
Main Contacts — 0.3 mΩ max @ 600 A
Auxiliary Contacts — 150 mΩ @ 1 A
Hot Switching Performance @ 400
Vdc:
200 A Make/Break — 4000 cycles
600 A Make/Break — 10 cycles
3000 A Make/Break — 3 cycles
4000 A Make or Pulse through Closed
Contacts
(1 ms risetime, 10 ms pulse duration)
— 10 cycles
Dielectric Withstand Voltage —
1 mA max @ 2800 Vrms
Insulation Resistance @ 500 Vdc
— 100 MΩ initial, 50 MΩ end of life
Mechanical/Environmental
Contact Arrangement —
Power Contacts: SPST (1 Form X)
Auxiliary Switches — SPDT (1 Form C)
Shock — (11 ms 1/2 sine, (operat-
ing): 25 g (Z axis)/35 g (X, Y axes)
peak
Sine Vibration — 55 to 2000 Hz: 25
g (Z axis), 35 g (X, Y axes)
Random Vibration (13.3 Grms):
@ 15 Hz: .002 g2/Hz
@ 100 Hz: .002 g2/Hz
@ 450 Hz: .12 g2/Hz
@ 900 Hz: .12 g2/Hz
@ 2000 Hz: .083 g2/Hz
Operating Temperature Range —
-55 to +125°C
Weight — 0.56 kg (1.2 lb.)
Mechanical Life — 100,000 cycles,
min.
Hermetically Sealed for Operation
in Harsh/Explosive Environments
Coil Data
24/28 Vdc models at 20°C
Consult TE for 12 Vdc model or other
voltages
Coil Voltage — 24 Vdc nom./32
Vdc max.
Pick Up — 13 Vdc
Dropout Voltage (max.) — 8 Vdc
Coil Resistance — 3.2 Ω/85 Ω
Pickup/Hold
Inrush Current (max @ 24 Vdc)
— 4.5 A
Inrush Time (max.) — 100 ms
Timing —
Operate Time — 25 ms typ.
Operate Bounce — 5 ms max.
Release Time — 15 ms max.
Simultaneity (Aux/Main) — 5 ms max.
KILOVAC High Voltage
DC Contactors
7
PAGE 21
KILOVAC High Voltage DC Contactors
KILOVAC KHR500 High-Voltage 600 Amp Contactors (Continued)
Part Numbering System KHR500 K S A N L
Series:
Contact Form:
A = Form X, SPST-NO, Double Make
K = Form X, SPST-NO, Double Make with 1 SPDT Auxiliary Contact
Coil Voltage:
S = 24/28 Vdc, Electric Cut-Throat Economizer
V = 12 Vdc, Electric Cut-Throat Economizer
Coil Leads:
A = 15˝ Coil/Auxiliary Leads (No Connector)
Coil/Auxiliary Connector:
N = None
Mounting:
L = Bottom Mount, No. 10 Hole, 5/16-24 Female Terminal Main Power Connection
Part No.
24/28 VDC 12 VDC
No Aux Contact KHR500ASANL KHR500AVANL
Aux Contact KHR500KSANL KHR500KVANL
Part Numbers
A2 A1
Coil + Integrated Electronic
Cut-Throat Economizer
NO (Brown)
NC (White)
COM (Green)
+
(Red)
_
(Black)
800
700
600
500
400
300
200
100
01251007550250
Ambient Temperature (°C)
Carry Current (A)
2 x 3/0 AWG or 350 kcmil Conductor
Max Term inal Tem p <170°C
Contacts Closing into >10 A dc
LABEL
5/16-24 UNF (2X)
7 THREADS DEPTH
HARDWARE SUPPLIED:
FLAT WASHER
LOCK WASHER
5/16-24 X 3/8 BHCS
MAX TORQUE 100 IN-LBS
2.23
[56.64] 2.13
[54.10]
.53
[13.46]
3.17
[80.52]
2.73
[69.34]
#10 MOUNTING HARDWARE
(NOT SUPPLIED)
TORQUE 30 IN-LBS MAX
COIL +VDC (RED)
COIL RTN (BLK)
AUX COM (GRN)
AUX NO (BRN) AUX NC (WHT)
COIL WIRES AND
AUX WIRES
22 AWG 6" LENGTH
(FROM TOP CAP)
Ø .23 [5.84] 2X
Ø 2.29
[58.17]
1.05
[26.67]
2.29
[68.33]
Schematic
Product Dimensions
Part Numbers
Schematic
Continuous Current vs. Ambient Temperature
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
KILOVAC K1K High-Voltage Contactor
Product Facts
n Handles up to
1000 A/1000 V
n Suitable for application
in harsh and explosive
environments
n No contact oxidation over
periods of non-use
n Bidirectional switching
n Main contacts not polarity
sensitive
n Bottom or buss bar mount
n Integrated dual-coil
electronic “cut-throat”
economizer with internal
suppression
n One of the smallest
1000 A/1000 V
hermetically-sealed
contactors in the industry
Applications
n Energy Storage/Battery
Storage
n Power Distribution
• Alternative Energy
n Electric Vehicles
(Military and Commercial)
n Test Equipment
Description
As one of the smallest, low-
est cost, hermetically sealed
1000 A/1000 V switching
devices in the Industry, the
KILOVAC K1K contactor
from TE Connectivity (TE)
operates reliably in harsh
and explosive environments
without oxidation or con-
tamination of contacts, even
after long periods of non-op-
eration. The K1K is well
suited for power switching
at voltages as low as 5 VDC
and as high as 1000 VDC.
Typical applications include
main disconnect contactor
for large battery bank appli-
cations, for carry and inter-
rupt battery fault currents
and other high current appli-
cations, power/motor control
circuit isolation, and circuit
protection and safety.
Electrical Data
Main Contacts
Contact Arrangement — SPST-NO
(Form X)
Voltage Rating (Max.) — 1000 VDC
Current Rating, Continuous —
1000 A (At 25°C ambient with four 4/0
conductors or equivalent)
Current Rating, Short Term — 1200
A/180 sec
Contact Resistance — 0.2 mΩ max.
at rated current
Hot-Switching Performance,
Resistive Load —
50 A/1000 VDC — 25,000 cycles
130 A/1000 VDC — 10,000 cycles
200 A/1000 VDC — 3500 cycles
100 A/600 VDC — 10,000 cycles
240 A/600 VDC — 2000 cycles
1000 VDC/1200 A — 4 cycles (Break
Only)
Maximum Pulse Through Closed
Contacts —
6000 A (half cycle, 60 Hz)
Dielectric Withstanding Voltage
over Life:
Between Open Contacts — 2800 Vrms
Contacts to Coil — 2800 Vrms/4000
VDC
End of Life Between Open Contacts —
2200 Vrms
Insulation Resistance over Life,
Terminal to Terminal; Terminals
to Coil —
Beginning of Life — 100 MΩ min. @
500 VDC
End of Life — 50 MΩ min. @ 500 VDC
Mechanical Life — 100,000 cycles
minimum
Environmental/Mechanical
Shock — 11 ms, 1/2 sine (operating),
20 g peak
Sine Vibration — 20 gpeak (operat-
ing) 55 to 2000 Hz
Operating Temperature Range —
-40°C to +105°C
Weight, Nominal — 1.02 kg
Sealing — Hermetic
Coil Data
Coil Data @ 20°C (Internal
Two-Coil Economizer)
Coil Voltage Range — 24 VDC
nom./32 VDC max.
Maximum Pickup Current — 5.5 A
Nominal Holding Current — 0.33 A
Pickup Voltage — 18 VDC
Dropout Voltage — 10 VDC
Pickup Pulse (Max) — 75 ms
Coil Resistance ±5% — 4.7 Ω
Pickup/72 Ω Hold
Coil Holding Power — 8 W
Main Contacts —
Operate Time (Max) — 50 ms
Operate Bounce (Typ.)— 5 ms
Release (Typ.) — 8 ms
KILOVAC High Voltage
DC Contactors
7
PAGE 23
KILOVAC High Voltage DC Contactors
KILOVAC K1K High-Voltage Contactor (Continued)
Part Numbering System
Brand:
K = KILOVAC
Basic Rating:
1K = 1000 V/1000 A
Size:
06 = Size 06 (EV202 Package)
Configuration:
X = Form X, Normally Open
Coil Voltage:
012E = 12 V Coil Economized
024E = 24 V Coil Economized
Coil lead length:
A = 15 inches
Contact Termination:
F = Finned Heat Sink Bus Bar (Nickel-Plated Aluminum)
G = Flat Bus Bar (Nickel-Plated Copper)
H = Four 1/4-20 UNC Female Threads, .187” Deep*
Mounting:
A = Bottom Mount
*User furnished bus bar must be equivalent to four 4/0 conductors. Torque to 45-55 in-lbs. per connection (5.1 – 6.2 Nm)
K 1K 06 X 024E A F A
4.52
[114.8]
0.68
[17.3]
1.36
[34.5]
Ø0.38
[9.65]
0.50
[12.7]
3.92
[99.6]
Ø0.23
[5.8]
3.31
[84.1]
3.79
[96.3]
A
LEAD LENGTH 15 ±0.5 [381 ±12.7]
(2 LEADS, RED/BLACK)
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
KILOVAC KCS01 Current-Sensing High-Voltage Contactor
Product Facts
n Saves space by eliminating
the need for external sensor
n Simplifies design
n Flexible configuration for
application needs
n Suitable for many
applications in harsh,
explosive, and corrosive
environments
n No oxidation or
contamination of contacts,
including long periods of
non-operation
n Extremely small size
n Lightweight contactor: 145
grams
n Bidirectional switching
n Main contacts not polarity
sensitive
n Not position sensitive:
mounts in any orientation
n Integrated dual-coil
electronic economizer with
coil suppression
n EMC compliant: no radiated
coil emissions
Applications
n Energy Storage/Battery
Storage
n Power Distribution
n Power Motion Control
n High-Voltage DC Converter
Systems
n Alternative Energy
n Military and Commercial
Electric Vehicles
n Test Equipment
Description
The new KILOVAC Current
Sensing contactors from TE
Connectivity (TE) eliminate
the need for a discrete cur-
rent sensor, saving the cus-
tomer money, weight and
space. The sensor function
also has a programmable
trip feature, allowing for
immediate, delayed or dis-
abled trip.
In addition to the integrated
current sensing feature,
KCS01 contactors are
rugged and hermetically
sealed, making them suit-
able for a variety of appli-
cations in harsh, corrosive
and explosive environments.
Even after long periods of
non-operation, the contacts
are impervious to oxidation
and contamination.
The KCS01 contactor
is extremely small and
lightweight. It features
bidirectional switching and
an integrated dual-coil
electronic economizer with
internal coil suppression,
and can be mounted in any
orientation. Main contacts
are not polarity sensitive,
and the KCS01 is EMC
compliant with no radiated
coil emissions.
Performance Data
Main Contacts
Contact Arrangement —
SPST-NO (Form X)
Voltage Rating, Switching —
600 VDC max.
Current Rating, Continuous —
±100 A
Current Rating, Short Term —
±200 A / 3 minutes
Contact Resistance, Main Contacts
— 0.75 mΩ max. at rated current
Hot-Switching Performance,
Resistive Load
1 A / 600 VDC — 1,000,000 cycles
100 A / 28 VDC — 100,000 cycles
100 A / 400 VDC — 25,000 cycles
100 A / 600 VDC — 20,000 cycles
1000 A / 28 VDC — 100 cycles
1000 A / 400 VDC — 10 cycles
1000 A / 600 VDC — 5 cycles
Maximum Pulse Through Closed
Contacts — 1250 A (half cycle, 60 Hz)
Dielectric Withstanding Voltage —
Between Open Contacts — 2200 Vrms
Contacts to Coil — 2200 Vrms / 1500
VDC
Insulation Resistance (Terminal to
Terminal; Terminals to Coil) —
Beginning of Life — 100 MΩ min. @
500 VDC
End of Life — 50 MΩ min. @ 500 VDC
Mechanical/Environmental
Mechanical Life — 1,000,000 cycles
Shock — 11 ms 1/2 sine (operating),
20 g peak
Sine Vibration — 20 g peak (operat-
ing), 55-2000 Hz
Operating Temperature Range —
-40 to +105 °C
RoHS Compliant
Weight, Nominal — 145 grams
Hermetically Sealed — Safe for
many harsh/corrosive environments
Nonoxidizing — No contact oxidation
over periods of nonuse
Mounting — Not position-sensitive
Noise Emission (at 100 mm distance)
— 70 dBa
KILOVAC High Voltage
DC Contactors
7
PAGE 25
KILOVAC High Voltage DC Contactors
12 V Coil 24 V Coil
Coil Voltage Range 9-14 VDC 18-28 VDC
Nominal Pickup Current 4.5 A 4.0 A
Nominal Holding Current 0.25 A 0.125 A
Pickup Voltage ≥9 VDC ≥18 VDC
Dropout Voltage ≤6 VDC ≤12 VDC
Pickup Pulse (max) 40 ms 40 ms
Coil Resistance ±5% Coil Holding Power 2.5 Ω Pickup/54 Ω Hold 2.7 W 7.5 Ω Pickup/210 Ω Hold 2.7 W
Main Contacts:
Operate Time (max) 20 ms 20 ms
Operate Bounce (max) 3 ms 3 ms
Release Time 5 ms 5 ms
Current Sensing
Sensing Range (8% accurate -40°C to +105°C) ±10 – 150 A ±10 – 150 A
Null Output @ I = 0 2.5 (±0.04) VDC 2.5 (±0.04) VDC
Output Voltage vs. Current (VDC) V(I) = ±I (.013) + 2.50
Current Trip Point vs. Setpoint Resistance See Pages 5 and 6
Hysteresis (-40°C to + 105°C) 8% of Full Scale Output
Coil Data
At 20°C (Internal Two-Coil Economizer)
LEADS ARE 26 AWG. LENGTH = 15" +/- 0.5"
FROM TOP OF TERMINAL SEAT
RED = +Vcoil
BLACK = RETURN
PURPLE = TRIP DELAY/DISABLE
ORANGE = CURRENT SENSE POWER
WHITE = CURRENT SENSE OUTPUT
BLUE = Rx CONNECTION
YELLOW = Rx CONNECTION
OBSERVE PROPER POLARITIES FOR CONTROL LINES
UNTERMINATED WIRES - USE ESD HANDLING PROCEDURES
MOUNTING - 2 PLCS (HARDWARE NOT SUPPLIED)
2 X M4 BOLT, LOCKWASHER AND WASHER
TORQUE: 20 IN-LBS (2.3 NM) MAX
LOAD TERMINALS-2 PLCS (HARDWARE NOT SUPPLIED)
2 X M5 BOLT, LOCKWASHER AND WASHER
TORQUE: 30-40 IN-LBS (3.4 TO 4.5 NM)
DEPTH: 7 THREADS MAX
CURRENT FLOW INTO THIS TERMINAL FOR
INCREASING SENSOR OUTPUT >2.5 VDC
0.70
[17.8]
Ø1.56
[39.5]
Ø0.18
[4.6]
1.82
[46.2]
2.12
[53.8]
1.79
[45.5]
0.30
[7.6]
1.50
[38.1]
1.72
[43.7]
KILOVAC KCS01 Current-Sensing High-Voltage Contactor (Continued)
Part Numbering System
Series:
KCS = KILOVAC Current Sensing
Size:
01 = Size 01 (EV100 Package)
Configuration:
X = Form X, Normally Open
Coil Voltage:
012E 12 V Coil Economized
024E 24 V Coil Economized
Coil Lead Length:
A = 15 Inch Coil Leads
Mounting Hardware:
C = M5 Female Terminals
Mounting style:
A = Bottom Mount
KCS 01 X 024E A C A
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
Load Life: Resistive Load Switching Current Carry vs. Time (≥ #4 AWG conductor)
Trip Function/Trip Delay (10-150A)
1 10 100 1000
400 V
600 V
28 V
1
10
100
1000
10,000
100,000
1,000,000
Current (A)
Cycles
Break only
above 600 A
0.01
0.1
1
10
100
1000
10,000
0 200 400 600 800 1000 1200
Time (s)
Current (A)
0
20
40
60
80
100
120
140
160
180
200
100 1000 10,000 100,000
External Resistor Value (Ohms)
Trip Current |A|
KILOVAC KCS01 Current-Sensing High-Voltage Contactor (Continued)
Input Output
Control
(Orange)
V+
(Red)
RTN
(Black)
Main Contact
Current (A)
Trip Disable/ Time
Delay
(Purple)
Trip Set Rx
(Blue)
Trip Set Ax
(Yellow)
Hall Output (V)
(White)
Main Contacts
Top Post
0 Vnom 0 0 NON-ACTIVE NON-ACTIVE 0 ON (NO TD)
0 0 0 0 NON-ACTIVE NON-ACTIVE 0 OFF (NO TD)
1 0 0 0 OPEN OPEN 2.5 OFF
1 Vnom 0 180 A ±7% OPEN 30K
4.84
(2.5 when relay
trip)
RELAY TRIP
OPEN
AFTER 14 ms
1
0 then 1
remove and
re-apply power
0≤167 A OPEN 30K 2.5 ON (NO TD)
1 Vnom 0 0 GND
(TRIP DISABLE) X 2.5 ON (NO TD)
1 Vnom 0 180 A ±7% GND
(TRIP DISABLE) X 4.84 ON (NO TD)
1 0 0 0 GND
(TRIP DISABLE) X 2.5 OFF (NO TD)
1 Vnom 0 0
1 µF is added
between
Purple and RTN
30K 2.5 ON (NO TD)
1 Vnom 0 180 A ±7%
10 µF is added
between
Purple and RTN
30K
4.84
(2.5 when relay
trip)
RELAY TRIP
OPEN
AFTER 82 ms
1 Vnom 0 180 A ±7%
10 µF is added
between
Purple and RTN
30K
4.84
(2.5 when relay
trip)
RELAY TRIP
OPEN
AFTER 720 ms
1
0 then Vnom
remove and
re-apply power
0≤167 A
10 µF is added
between
Purple and RTN
30K 2.5 ON (NO TD)
Trip Setpoint Resistor (10 A to 150 A)
Connect Rx across Blue and Yellow for Trip Setpoint
Connect Purple to RTN to Disable Trip Function or Connect Purple
to External Capacitor Tied to RTN to Delay Trip, 7 ms/µF
Connect Orange to V+ To Enable Trip and Current Sensing
Reset Tripped Contacts by Cycling V+ Off to On
Intrinsic Trip Delay (Blue/Yellow Not Connected to Rx) = 14 ms
KILOVAC High Voltage
DC Contactors
7
PAGE 27
KILOVAC High Voltage DC Contactors
KILOVAC KCS01 Current-Sensing High-Voltage Contactor (Continued)
Timing Diagram
Connection Diagram
Contacts
Open
Closed
I (Contacts)
0A
I trip
V+in (Red)
0V
Vcontrol (0range)
0V
14 ms
>14 ms
+24/12 VDC RED
RTN BLACK
SENSOR/TRIP EN ORANGE
DISABLE/DELAY PURPLE
SENSOR_OUT WHITE
BLUE Rx
YELLOW Rx
KCS01X012/KCS01X024
Rx
V(I)
GND
V+ (12 OR 24 VSX NOM)
7 ms/µF
Cx
GND
GND
N/C
ENERGIZE/CLOSE CONTACTS USING SWITCH OR SOLID
STATE DEVICE-LOW SIDE DRIVE SHOWN
LEAVE PURPLE NC FOR TRIP ENABLE
GROUND FOR TRIP DISABLE
CONNECT Cx FOR TRIP DELAY, 7 ms/µF
CONNECT ORANGE TO V+ FOR SENSING-
SENSING ACTIVE ONLY WITH LOW SIDE DRIVE ENABLED AS SHOWN
SENSOR INPUT SINK 15 mA MAX
V(I) = ±I (.013) + 2.50
+24/12 VDC RED
RTN BLACK
SENSOR/TRIP EN ORANGE
DISABLE/DELAY PURPLE
SENSOR_OUT WHITE
BLUE Rx
YELLOW Rx
KCS01X012/KCS01X024
Rxx
V(I)
GND
V+ (12 OR 24 VDC NOM)
7ms/µF
Cxx
GND
GND
N/C
ENERGIZE/CLOSE CONTACTS USING SWITCH OR SOLID
STATE DEVICE-HIGH SIDE DRIVE SHOWN
LEAVE PURPLE NC FOR TRIP ENABLE
GROUND FOR TRIP DISABLE
CONNECT Cxx FOR TRIP DELAY, 7 ms/µF
CONNECT ORANGE TO V+ FOR SENSING-
SENSING ACTIVE WITH/WITHOUT HIGH SIDE DRIVE
ENABLED AS SHOWN
SENSOR INPT SINK 15 mA MAX
CONNECT Rxx VALUE PER
TRIP FUNCTION/TRIP DELAY GRAPH
TO SET TRIP LEVEL
V(I) = ±I (.013) + 2.50
CONNECT Rxx VALUE PER
TRIP FUNCTION/TRIP DELAY GRAPH
TO SET TRIP LEVEL
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
KILOVAC KCS03 Current-Sensing High-Voltage Contactor
Product Facts
n Saves space by eliminating
the need for external sensor
n Simplifies design
n Flexible configuration for
application needs
n Suitable for application in
many harsh, explosive, and
corrosive environments
n No oxidation or
contamination of contacts,
including long periods of
non-operation
n Extremely small size
n Lightweight contactor: 500
grams
n Bidirectional switching
n Main contacts not polarity
sensitive
n Not position sensitive:
mounts in any orientation
n Integrated dual-coil
electronic economizer with
coil suppression
n EMC compliant: no radiated
coil emissions
Applications
n Energy Storage/Battery
Storage
n Power Distribution
n Power Motion Control
n High-Voltage DC Converter
Systems
n Alternative Energy
n Military and Commercial
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
Description
The new KILOVAC Current
Sensing contactors from
TE Connectivity (TE) elimi-
nate the need for a discrete
current sensor, saving the
customer money, weight
and space. The sensor
function also has a program-
mable trip feature, allowing
for immediate, delayed or
disabled trip.
In addition to the integrated
current sensing feature,
KCS03 contactors are
rugged and hermetically
sealed, making them suit-
able for a variety of appli-
cations in harsh, corrosive
and explosive environments.
Even after long periods of
non-operation, the contacts
are impervious to oxidation
and contamination.
The KCS03 contactor
is extremely small and
lightweight. It features
bidirectional switching and
an integrated dual-coil
electronic economizer with
internal coil suppression,
and can be mounted in any
orientation. Main contacts
are not polarity sensitive,
and the KCS03 is EMC
compliant with no radiated
coil emissions.
Performance Data
Physical Data
Contact Arrangement — SPST-NO
(Form X)
Voltage Rating, Switching — 600
VDC max.
Current Rating, Continuous —
±600 A
Current Rating, Short Term —
±1200 A / 30 sec
Contact Resistance, Main Contacts
— 0.2 mΩ max. at rated current
Hot-Switching Performance,
Resistive Load
1 A / 600 VDC: 1,000,000 cycles
100 A / 28 VDC: 100,000 cycles
100 A / 400 VDC: 25,000 cycles
100 A / 600 VDC: 20,000 cycles
1000 A / 28 VDC: 100 cycles
1000 A / 400 VDC: 10 cycles
1000 A / 600 VDC: 5 cycles
Maximum Pulse Through Closed
Contacts — 3000 A (half cycle, 60 Hz)
Dielectric Withstanding Voltage —
Between Open Contacts: 2800 Vrms
Contacts to Coil: 2800 Vrms / 4000 VDC
Insulation Resistance (Terminal to
Terminal; Terminals to Coil) —
Beginning of Life — 100 MΩ min. @
500 VDC
End of Life — 50 MΩ min. @ 500 VDC
General Characteristics
Mechanical/Environmental
Mechanical Life— 1,000,000 cycles
Shock— 11 ms 1/2 sine (operating),
20 g peak
Sine Vibration— 20 g peak (operat-
ing), 55-2000 Hz
Operating Temperature Range—
-40 to +105 °C
RoHS Compliant
Weight, Nominal— 500 grams
Hermetically Sealed— Safe for
many harsh/corrosive environments
Nonoxidizing— No contact oxidation
over periods of nonuse
Mounting— Not position-sensitive
Noise Emission (at 100 mm distance)—
70 dBa
KILOVAC High Voltage
DC Contactors
7
PAGE 29
KILOVAC High Voltage DC Contactors
KILOVAC KCS03 Current-Sensing High-Voltage Contactor (Continued)
Coil Voltage Part No.
12 VDC KCS03X012EAAA
24 VDC KCS03X024EAAA
Part Numbers
CURRENT FLOW INTO
THIS
TERMINAL FOR
INCREASING SENSOR
OUTPUT >2.5 VDC
M5 x 1.25 NUT
HARDWARE INCLUDES
FLAT WASHER AND LOCKWASHER
MAX. TORQUE: 90 IN-LBS. [10 N-m]
HARNESS:
WIRE LENGTHS 15" NOMINAL
ALL CONDUCTORS M22759/11, 22 AWG
RED = V+
BLACK = RTN
WHITE (2 EA) AUX COM-NO
PURPLE = TRIP DISABLE/PROGRAM TIME DELAY
ORANGE = CONNECT TO V+ FOR TRIP SENSING AND
CURRENT SENSING
BROWN = CURRRENT SENSE OUTPUT
BLUE = Rx
YELLOW = Rx
2.69
[68.33]
3.17
[80.52]
1.05
[26.67]
Ø0.23
[5.84]
Ø2.29
[58.17]
OBSERVE PROPER POLARITIES FOR CONTROL LINES
UNTERMINATED WIRES - USE ESD HANDLING PROCEDURES
2.87
[72.9]
0.50
[12.7]
Part Numbering System
Series:
KCS = KILOVAC Current Sensing
Size:
03 = Size 03 (EV200 Package)
Configuration:
X = Form X, Normally Open
Coil Voltage :
012E 12 V Coil Economized
024E 24 V Coil Economized
Coil Lead Length:
A = 15 Inch Coil Leads
Mounting Hardware:
A = M8 Male Terminals
Mounting Style:
A = Bottom Mount
KCS 03 X024E A A A
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
KILOVAC KCS03 Current-Sensing High-Voltage Contactor (Continued)
Load Life: Resistive Load Switching
Current Carry vs. Time (≥350 KCMIL Conductor)
Trip Function/Trip Delay (50 A to 630 A)
110100 1000
400 V
600 V
28 V
1
10
100
1000
10,000
100,000
1,000,000
Current (A)
Cycles
Break only above 650 A
0.01
0.1
1
10
100
1000
10,000
0500 100015002000 2500 3000 3500
Time
Rate
Current (A)
Time (s)
1
10
100
T
emperature Rise (°C/s)
0
50
100
150
200
250
300
350
400
450
500
550
600
650
0 1000 2000 3000 4000 5000 6000
Trip Current |A|
External Resistor Value (Ohms)
KILOVAC High Voltage
DC Contactors
7
PAGE 31
KILOVAC High Voltage DC Contactors
Input Output
Sensing
Control
(Orange)
V+
(Red)
RTN
(Black)
Main Contacts
(Current +/-
ADC)
Trip Disable/
Time Delay
(Purple)
Trip Set Rx
(Blue)
Trip Set Ax
(Yellow)
Hall Output
(VDC)
(Brown)
Main
Contacts
Aux. Contact
(N.O.)
White/White
09-14 or
18-28 0 0 NON-ACTIVE NON-ACTIVE 0 ON (NO TD) ON (NO TD)
0 0 0 0 NON-ACTIVE NON-ACTIVE 0 OFF (NO TD) OFF (NO TD)
V+ 0 0 0 OPEN OPEN 2.5 OFF OFF
V+ 9-14 or
18-28 0 500 A ± 7% OPEN 4.2 K
4.145
(2.5 V when
tripped)
RELAY
TRIP OPEN
AFTER 14 ms
RELAY
TRIP OPEN
AFTER 14 ms
V+
0, then
9-14 or 18-28
remove and
re-apply power
0≤464 OPEN 4.2 K 2.5 ON (NO TD) ON (NO TD)
V+ 9-14 or
18-28 0 0 GND
(TRIP DISABLE) X 2.5 ON (NO TD) ON (NO TD)
V+ 9-14 or
18-28 0 500 A ± 7% GND
(TRIP DISABLE) X 4.145 ON (NO TD) ON (NO TD)
V+ 0 0 0 GND
(TRIP DISABLE) X 2.5 OFF (NO TD) OFF (NO TD)
V+ 9-14 or
18-28 0 0
1 µF is added
between
these two wires
4.2 K 2.5 ON (NO TD) ON (NO TD)
V+ 9-14 or
18-28 0 500 A ± 7%
10 µF is added
between
these two wires 4.2 K
4.145
(2.5 V when
tripped)
RELAY
TRIP OPEN
AFTER 82 ms
RELAY
TRIP OPEN
AFTER 82 ms
V+ 9-14 or
18-28 0 500 A ± 7%
100 µF is added
between
these two wires 4.2 K
4.145
(2.5 V when
tripped)
RELAY
TRIP OPEN
AFTER 720 ms
RELAY
TRIP OPEN
AFTER
720 ms
V+
0, then
9-14 or 18-28
remove and
re-apply power
0≤464
100 µF is added
between
these two wires
4.2 K 2.5 ON (NO TD) ON (NO TD)
Trip Setpoint Resistor (10 A to 150 A)
Connect Rx across Blue and Yellow for Trip Setpoint
Connect Purple to RTN to Disable Trip Function or Connect Purple to External Capacitor Tied to
RTN to Delay Trip, 7 ms/µF
Connect Orange to V+ To Enable Trip and Current Sensing
Reset Tripped Contacts by Cycling V+ Off to On
Intrinsic Trip Delay (Blue/Yellow Not Connected to Rx) = 14 ms
KILOVAC KCS03 Current-Sensing High-Voltage Contactor (Continued)
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
Timing Diagram
Connection Diagram
Contacts
Open
Closed
I (Contacts)
0A
I trip
V+in (Red)
0V
Vcontrol (0range)
0V
14 ms
>14 ms
+24/12 VDC RED
RTN BLACK
SENSOR/TRIP EN ORANGE
DISABLE/DELAY PURPLE
AUX_COM WHITE
AUX_NO WHITE
SENSOR_OUT BROWN
BLUE Rx
YELLOW Rx
KCS03X012/KCS03X024
Rx
V(I)
GND
V+ (12 OR 24 VDC NOM)
7 ms/µF
Cx
GND
GND
N/C
ENERGIZE/CLOSE CONTACTS USING SWITCH OR SOLID
STATE DEVICE-LOW SIDE DRIVE SHOWN
LEAVE PURPLE NC FOR TRIP ENABLE
GROUND FOR TRIP DISABLE
CONNECT Cx FOR TRIP DELAY, 7 ms/µF
CONNECT ORANGE TO V+ FOR SENSING-
SENSING ACTIVE ONLY WITH LOW SIDE DRIVE ENABLED AS SHOWN
SENSOR INPUT SINK 15 mA MAX
V(I) = ±I (.0034) + 2.50
+24/12 VDC RED
RTN BLACK
SENSOR/TRIP EN ORANGE
DISABLE/DELAY PURPLE
AUX_COM WHITE
AUX_NO WHITE
SENSOR_OUT BROWN
BLUE Rx
YELLOW Rx
KCS03X012/KCS03X024
Rxx
V(I)
GND
V+ (12 OR 24 VDC NOM)
7 ms/µF
Cxx
GND
GND
N/C
ENERGIZE/CLOSE CONTACTS USING SWITCH OR SOLID
STATE DEVICE-HIGH SIDE DRIVE SHOWN
LEAVE PURPLE NC FOR TRIP ENABLE
GROUND FOR TRIP DISABLE
CONNECT Cxx FOR TRIP DELAY, 7 ms/µF
CONNECT ORANGE TO V+ FOR SENSING-
SENSING ACTIVE WITH/WITHOUT HIGH SIDE DRIVE
ENABLED AS SHOWN
SENSOR INPT SINK 15 mA MAX
V(I) = ±I (.0034) + 2.50
CONNECT Rxx VALUE PER
TRIP FUNCTION/TRIP DELAY GRAPH
TO SET TRIP LEVEL
CONNECT Rxx VALUE PER
TRIP FUNCTION/TRIP DELAY GRAPH
TO SET TRIP LEVEL
KILOVAC KCS03 Current-Sensing High-Voltage Contactor (Continued)
KILOVAC High Voltage
DC Contactors
7
PAGE 33
KILOVAC High Voltage DC Contactors
KILOVAC EV202 High-Voltage Contactors
Product Facts
n Suitable for application
in harsh, explosive, and
corrosive environments
n EMC compliant: no radiated
coil emissions
n Extremely small size
n Lightweight contactor:
0.77 kg
n Bidirectional switching
n Main contacts not polarity
sensitive
n Not position sensitive:
mounts in any orientation
n Integrated dual-coil
electronic economizer with
coil suppression
Applications
n Energy Storage/Battery
Storage
n Power Distribution
n Power Motion Control
n High-Voltage DC Converter
Systems
n Alternative Energy
n Military and Commercial
Electric Vehicles
n Test Equipment
Description
Hermetically sealed and
designed for harsh environ-
ments and loads, KILOVAC
EV202 high-voltage contac-
tors from TE Connectivity
(TE) offers exceptional
performance in an extremely
small and lightweight
device.
Available with 12 or 24-V
coils, the contactors are
suited to 270 and 400-VDC
power systems. They are
available with two optional
auxiliary contacts.
High break levels—2000 A
at 270 VDC and 700 A at
400 VDC—help increase
system flexibility and reli-
ability.
EV202 contactors provide
reliable and long-lasting
performance in military and
commercial electric ground
vehicles, energy storage
systems, and power distri-
bution and motion control
applications.
Electrical Data
Configuration: Double pole, single throw, normally open
Voltage Rating, Main Contacts: 600 VDC, max.
Make Current: 700 A, max.
DWV and Insulation Resistance over Life, Terminal to Terminal/
Terminals to Coil
Dielectric Withstand Voltage: 1 mA max @ 2200 Vrms
Insulation Resistance: 50 mΩ min. @ 500 VDC
Hot Switch Life:
Coil Voltage, nom./max. 12/16 VDC 24/32 VDC
Pick up voltage, max. (applied as
step voltage only)
8 VDC 16 VDC
Dropout Voltage 2.5–4 VDC 3–8 VDC
Coil Inrush Current @ V-nom., max. 5 A 4.5 A
Coil Inrush Time, nom./max. 75/150 ms 75/150 ms
Hold Current @ V-nom., max. 0.6 A 0.2 A
Coil Suppression, max. 40 VDC 60 VDC
Operate Times
Operate Time, nom./max.
Operate Bounce, nom./max.
Release Time, nom./max.
13/20 ms
3/10 ms
5 ms
13/20 ms
3/10 ms
5 ms
Release Time, max. (including max.
arc time)
25 ms 25 ms
Make/Break Current @ Voltage Hot Switch Life
100 A 270 VDC 40,000
400 VDC 10,000
250 A 270 VDC 7500
400 VDC 2500
700 A Break Only 400 VDC 10
2000 A Break Only 270 VDC 2
Coil Data (over -40°C to +85°C unless noted)
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
KILOVAC EV202 High-Voltage Contactors (Continued)
Product Dimensions (Inches)
Typical Part Number EV202 M S B F D
Series:
EV202 = Two Form X,
DPST-NO-DM Contactor
Auxiliary Contact Outputs (SPDT form C):
A = None
M = Two
Coil Voltage:
S = 24 V
V = 12 V (With Built-In Dual Coil Economizer)
Coil and Aux Wire Length (inches):
A = 15.3
B = 6
X = Customer-Specified Configuration
Coil and Aux Connector:
N = None
F = D-Subminiature Plug on Flying Leads
(May Affect Wire Length)
Mounting and Power Terminals:
D = Two M5 Bottom Mount with Four M6 X 1 Female
thread terminals
5.0 [127]
(Not to Scale)
1.00
[25.40]
1.00
[25.40] 3.312
[84.12]
2.32
[58.93]
3.79
[96.27]
0.50
[12.70] 2.72
[69.09]
2.790
[70.87]
2.420
[61.47]
M6 x 1.0-8H
Female Thread
Ø0.228
[5.79]
9-Pin Sealed
D-Subminiature
Plug
A1 A2
B1 B2
HOLD COIL
PICK-UP COIL
1
2
3
4
5
7
8
9
6
B1 AUX: COM
NO
NC
COIL RTN
COIL POS
BLANK
B1 AUX: COM
NO
NC
Economizer
Circuit
DB9 Plug
Connector
Typical Schematic
(Shown with Auxiliary Contacts)
Optional Auxiliary Contacts
Configuration — Two SPDT switch outputs
Ratings — 30 VDC/2A switching or 5 V/5 mA signal
Environmental
Operating Temperature Range — -55°C to + 85°C
Hermetically Sealed — Safe for harsh/corrosive
environments
Nonoxidizing — No contact oxidation over periods
of nonuse
RoHS Compliant
Economizer — Integrated electronically switched coil economizer with coil
suppression
EMC Compliant — No radiated coil emissions
Mechanical
Shock — 11 ms 1/2 sine (operating): 20 g peak
Sine Vibration — 10 g peak: 10 to 2000 Hz
Random Vibration — 14 grms:
Bidirectional Switching — Main contacts not polarity sensitive
Mounting — Mounts in any orientation; not position sensitive
Mechanical Life — 100,000 cycles
Weight — 0.77 kg
Hz 15 100 300 900 2000
g2/Hz 0.01 0.01 0.2 0.2 0.01
KILOVAC High Voltage
DC Contactors
7
PAGE 35
KILOVAC High Voltage DC Contactors
KILOVAC EV200 Series Contactor With 1 Form X (SPST-NO)
Contacts Rated 500+ Amps, 12-900 Vdc
EV200 Series Contactor
(CZONKA Relay, Type
Product Facts
n 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)
n Built-in coil economizer
— only 1.7W hold
power @ 12VDC and it
limits back EMF to 0V.
Models requiring external
economizer also available
n Optional auxiliary contact
for easy monitoring of
power contact position
n Hermetically sealed
— intrinsically safe,
operates in explosive/
harsh environments with no
oxidation or contamination
of coil or contacts,
during long periods of
non-operation
n Versatile coil/power
connections
n UL Recognized
for the U.S. and
Canada (File E208033)
All contact ratings & coil
versions may not be UL
Recognized
n CE marked for
EC applications
n AIAG QS9000 designed,
built and approved
n RoHS versions available
Performance Data
Contact Arrangement, Power
Contacts — 1 Form A (SPST-NO)
Rated Operating Voltage —
12 - 900 VDC
Continuous (Carry) Current,
Typical — 500 A @ 85°C, 400 mcm
conductors
Consult Factory for required
conductors for higher (500+ A)
currents
Make/Break Current at Various
Voltages 1 — See graph next page
Break Current at 320VDC 1 —
2,000 A, 1 cycle 3
Contact Resistance, Typ.
(@200A) — 0.2 mohms
Load Life — See graph next page
Mechanical Life — 1 million cycles
Contact Arrangement, Auxiliary
Contacts — 1 Form A (SPST-NO)
Aux. Contact Current, Max. —
2A @ 30VDC / 3A @ 125VAC
Aux. Contact Current, Min. —
100mA @ 8V
Aux. Contact Resistance, Max. —
0.417 ohms @ 30VDC /
.150 ohms @ 125VAC
Operate Time @ 25°C —
Close (includes bounce), Typ. — 15 ms
Bounce (after close only), Max. — 7 ms
Release (includes arcing),
Max @ 2000A — 12 ms
Dielectric Withstanding Voltage —
2,200 Vrms @ sea level (leakage <1mA)
Insulation Resistance @ 500VDC —
100 megohms 2
Shock, 11ms 1/2 Sine, Peak,
Operating — 20 G
Vibration, Sine, 80-2000Hz.,
Peak — 20 G
Operating Ambient Temperature
—
-40°C to +85°C
Weight, Nominal — .95 lb. (.43 kg)
Notes:
1 Main power contacts
2 50 at end of life
3 Does not meet dielectric & IR after
test, 1700 amp for unit with Aux.
Contacts
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
Ordering Information
Typical Part Number EV200 A A A N A
Series:
EV200 = 500+ Amp, 12-900VDC Contactor
Contact Form:
A = Normally Open
H = Normally Open with NO Aux. Contacts
G = Normally Open with NC 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)
Coil Terminal Connector:
N = None
C = Molex Mini-fit Jr, 2 Skt, 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
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC EV200 Series (CZONKA Relay, Type III) (Continued)
Outline Dimensions
AUXILIARY CONTACT LEADS
COIL LEADS
WHITE = AUXILIARY CONTACT
(WHEN ORDERED)
BLACK = – COIL
RED = + COIL
SEE COIL WIRE
LENGTH IN P/N
STAINLESS 2.85 ± .025
(72.3 ± .63)
.5 ± .01
(12.6 ± .26)
2.05 ± .02
(52 ± .51)
2.45 ± .02
(62.23 ± .51)
.55 ± .025
(14.04 ± .63)
2.20 ± .025
(55.81 ± .63)
2.04 ± .02 DIA
(51.94 ± .51)
3.17 ± .01
(80.48 ± .26)
2.29 ± .02 DIA
(58.19 ± .51)
1.05 ± .01
(26.67 ± .26)
1.65 ± .01
(42.0 ± .26)
2.688 ± .01
(68.28 ± .26)
A1
"+" POSITIVE TERMINAL
A2 "–" NEGATIVE TERMINAL
.225 ± .01DIA
(5.72 ± .26)
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)
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)
Estimated Make & Break Power Switching Ratings
NOTES:
1) For resistive loads with 300µH 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.
100,000
10,000
1,000
100
10
11,000 10,000
100101
Make and Break Power Switching Region Break Only Above 650A
650A
Estimated Life (Cycles)
Load Current (A)
1800 VDC
900 VDC
600 VDC
400 VDC
270 VDC
120 VDC
28 VDC
80% Minimum
Pre Charge
90% Nominal
Pre Charge
Time (ms)
Current (A)
EV200 Capacitive Make Test Curves for Pre-Charged Motor Controller
650
600
550
500
450
400
350
300
250
200
150
100
50
0
0.0 0.5 1.0 1.5 2.0
700
KILOVAC High Voltage
DC Contactors
7
PAGE 37
KILOVAC High Voltage DC Contactors
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC EV200B Series Contactor With 1 Form Y (SPST-NC)
Contacts Rated 500+ Amps, 12-900 Vdc
Product Facts
n Normally closed version
of popular EV200 series
contactors
n Designed to be the
smallest, lowest cost,
lightest weight sealed
contactor in the industry at
its current rating
n Optional auxiliary contacts
for monitoring position of
power contacts
n Hermetically sealed —
operates in explosive/
harsh environments with no
oxidation or contamination
of coil or contacts
during long periods of
non-operation
n Not position sensitive,
can be mounted in any
orientation
n RoHS versions available
Ordering Information
Typical Part Number EV200 B A A N A
Series:
EV200 = 500+ Amp, 12-900VDC Contactor
Contact Form:
B = Normally Closed
D = Normally Closed, 1 SPDT Aux.
Coil Voltage (with Economizer):
A = 12/24 Vdc
Coil Terminals:
A = 15.3 in. (300 mm)
Coil Terminal Connector:
N = None
Mounting & Power Terminations:
A = Bottom Mount & Male 10 Max. M8
Threaded Terminals
Physical Data
Contact Arrangements —
Main Contacts — SPST, Normally
Closed
Dimensions — See drawing
Weight, Nominal — .95 lb. (.43 kg)
Environmental Data
Shock, 11ms 1/2 Sine
(Operating) — 30 Gpeak (Closed)
10 Gpeak (Open)
Sine Vibration, 10 Gpeak —
55-2000 Hz
Random Vibration, 7.1 Grms —
15 Hz (.001 G2/Hz), 100 Hz (.04 G2/Hz),
1000 Hz (.04 G2/Hz), 1500 Hz (.02 G2/Hz)
Operating Temperature Range —
-40°C to +85°C
Electrical Data
Voltage Rating —
Main Contacts (Max) — 750 Vdc
Current Rating, Continuous —
Main Contacts 1 — 500A
Contact Resistance —
Main Contacts 2 —
0.2 mΩ max above 300A
0.3 mΩ max between 50 and 300A
Hot Switching Performance
(Positive Polarity) 3 —
200A make/ break @ 270Vdc —
10,000 cycles
600A make/ break @ 360Vdc —
100 cycles
800A break only @ 360Vdc —
15 cycles
1500A break only @ 360Vdc — 1 cycle
Mechanical Life (Min) —
1 million cycles
Dielectric Withstand Voltage —
Terminal to Terminal/ Terminals to Coil
—
1mA max @ 2,200 Vrms
Insulation Resistance —
Terminal to Terminal/ Terminals to Coil
—
100MΩ min @ 500Vdc new
50MΩ min @ 500Vdc end of life
Coil Data 4
Nominal Coil Voltage 5 —
Low range — 9.6-14 Vdc
High range — 19-28 Vdc
Pick Up (Max) @ 25°C —
9.6/18.5 Vdc
Pick Up @ Max Coil Temperature —
10.5/22 Vdc
Hold (Min) — 6/12 Vdc
Dropout (Min) — 4/9 Vdc
Pickup Current, Peak 6 @ 25°C
— 6 A
Operate Specs @ 25°C —
Operate Time (Typ) — 15 ms
Operate Bounce (Max) — 5 ms
Release Time (Typ) — 15 ms
Economizer Operating Frequency
— 18 kHz
Hold Current —
0.9A/12 Vdc
0.3A/24 Vdc
Notes:
1 Ambient conditions and conductor
design affect rating. Terminal
temperature rise should be 75°C
max above ambient. Keep relay
terminals below 150°C max con-
tinuous, 175°C max for two hours,
and 200°C for 1 minute.
2 Stabilized reading. Contact resis-
tance may exceed spec in the first
10 minutes of current carry.
3 Units are polarity sensitive.
Approximately 50% de-rating
for reverse polarity switching.
Consult factory for review of
specific requirements.
4 Over temperature range unless
noted.
5 Voltage ranged sensed by con-
tactor 10 ms after application of
source voltage.
6 Pickup duration 100 ms.
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC EV200B Series Contactor (Continued)
Outline Dimensions
AUXILIARY CONTACT LEADS
COIL LEADS
WHITE = AUXILIARY CONTACT
(WHEN ORDERED)
BLACK = – COIL
RED = + COIL
SEE COIL WIRE
LENGTH IN P/N
STAINLESS 2.85 ± .025
(72.3 ± .63)
.5 ± .01
(12.6 ± .26)
2.05 ± .02
(52 ± .51)
2.45 ± .02
(62.23 ± .51)
.55 ± .025
(14.04 ± .63)
2.20 ± .025
(55.81 ± .63)
2.04 ± .02 DIA
(51.94 ± .51)
3.17 ± .01
(80.48 ± .26)
2.29 ± .02 DIA
(58.19 ± .51)
1.05
±
.01
(26.67 ± .26)
1.65 ± .01
(42.0 ± .26)
2.688 ± .01
(68.28 ± .26)
A1
"+" POSITIVE TERMINAL
A2 "–" NEGATIVE TERMINAL
.225 ± .01DIA
(5.72 ± .26)
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)
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)
KILOVAC High Voltage
DC Contactors
7
PAGE 39
KILOVAC High Voltage DC Contactors
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
Product Facts
n Latching version of popular
EV200 Series
n Designed to be the
smallest, lowest cost,
lightest weight sealed
contactor in the industry at
its current rating
n Optional auxiliary contacts
for monitoring position of
power contacts
n Hermetically sealed —
operates in explosive/
harsh environments with no
oxidation or contamination
of coil or contacts
during long periods of
non-operation
n Not position sensitive,
can be mounted in any
orientation
n RoHS versions available
KILOVAC EV200P Series Latching Contactor With 1 Form X (SPST Latch)
Contacts Rated 500+ Amps, 12-900 Vdc
Ordering Information
Typical Part Number EV200 P 4 A N A
Series:
EV200 = 500+ Amp, 12-900VDC Contactor
Contact Form:
P = Latching
F = Latching with 1 SPDT Aux.
Coil Voltage:
4 = 12 Vdc
5 = 24 Vdc
6 = 48 Vdc
Coil Terminations:
A = 15.3 in. (300 mm)
Coil Termination Connector:
N = None
Mounting & Power Terminals:
A = Bottom Mount & Male 10mm x
M8 Threaded Terminals
Physical Data
Contact Arrangements —
Main Contacts — SPST, Latching
Auxiliary Contacts 1 — Up to 2 Form A
Dimensions — See drawing
Weight, Nominal — .95 lb. (.43 kg)
Environmental Data
Shock, 11ms 1/2 Sine
(Operating) — 30 Gpeak
Sine Vibration, 20 Gpeak —
55-2000 Hz
Random Vibration, 14.06 Grms —
15 Hz (.002 G2/Hz), 100 Hz (.002 G2/Hz),
450 Hz (.12 G2/Hz), 900 Hz (.12 G2/Hz),
2000 Hz (.083 G2/Hz)
Operating Temperature Range —
-40°C to +85°C
Electrical Data
Voltage Rating —
Main Contacts (Max) — 750 Vdc
Current Rating, Continuous —
Main Contacts 2 — 500A
Contact Resistance —
Main Contacts 3 —
0.2 mΩ max above 300A
0.3 mΩ max between 50 and 300A
Hot Switching Performance
(Positive Polarity) 4 —
200A make/ break @ 270Vdc —
10,000 cycles
600A make/ break @ 360Vdc —
100 cycles
800A break only @ 360Vdc —
15 cycles
2000A break only @ 360Vdc — 1 cycle
Mechanical Life (Min) —
1 million cycles
Dielectric Withstand Voltage —
Terminal to Terminal/ Terminals to Coil
—
1mA max @ 2,200 Vrms
Insulation Resistance —
Terminal to Terminal/ Terminals to Coil
—
100MΩ min @ 500Vdc new
50MΩ min @ 500Vdc end of life
Coil Data 5
Nominal Coil Voltage 6 — 12 Vdc
Pick Up/Latch (Max) @ 25°C —
9 Vdc
Hold (Min) — N/A
Reset (Max)/Dropout (Min) —
9 Vdc
Duty Cycle, Max 7 — 20%
Coil Resistance @ 25°C — 2.5 Ω
Operate Specs @ 25°C —
Operate Time (Typ) — 15 ms
Operate Bounce (Max) — 7 ms
Release Time (Max) — 15 ms
Notes:
1 Product can be configured alter-
nately with form B or C auxiliary
switches if required. This changes
the product part number, depend-
ing on specific auxiliary configura-
tion. Consult TE for availability and
part number
2 Ambient conditions and conductor
design affect rating. Terminal
temperature rise should be 75°C
max above ambient. Keep relay
terminals below 150°C max con-
tinuous, 175°C max for two hours,
and 200°C for 1 minute.
3 Stabilized reading. Contact resis-
tance may exceed spec in the first
10 minutes of current carry.
4 Units are polarity sensitive.
Approximately 50% de-rating
for reverse polarity switching.
Consult factory for review of
specific requirements.
5 Over temperature range unless
noted. Suggested coil pulse =
50-100 ms.
6 24V and 48V coils available on
request — consult factory.
7 Intermittent Duty Coil. Coil over-
heating can occur if duty cycle
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC EV200P Series Latching Contactor (Continued)
Outline Dimensions
KILOVAC High Voltage
DC Contactors
7
PAGE 41
KILOVAC High Voltage DC Contactors
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC EV100 Series Contactor With 1 Form X
Contacts Rated 100 Amps Continuous, 600 Vdc
Product Facts
n Hermetically sealed
n Operates in explosive/
harsh environments without
oxidation or contamination
of contacts, during long
periods of non-operation
n 8kV isolation between open
contacts permits use for
high voltage isolation and
carry
n Coil economizer allows for
operation between 9-36 VDC
n Designed and built in
accordance with AS 9100
Description
Low cost, 600 Vdc, 100
amp, hermetically sealed
DC contactor
Economized coil for
low power consumption
between 9-36 VDC
Bottom mount, not position
sensitive
One million cycle mechani-
cal life
Applications
Power/motor control circuit
isolation, circuit protection
and safety in industrial
machinery
Automotive battery switching
and backup
Solar inverter switching
Automotive pre-charge
Test Equipment
Power distribution
Electrical
Contact arrangement:
SPST-NO (Form X., Double
Make)
Voltage rating:
5-600 Vdc at 100 Amps
50K cycles Make/Break:
50 Amps at 400 Vdc
25K cycles Make/Break:
50 Amps at 600 Vdc
Holding current:
0.15 Amps at 24 Vdc
Operate time: 30 ms max.
Physical or Other Properties
Hermetically sealed
Safe for harsh/corrosive
environments
No contact oxidation over
periods of non-use
Mechanical
Small size: 1.5” x 1.5”
approximately
Weight: 130 grams
Performance Data
Physical Data
Contact Arrangement, Main
Contacts — SPST-NO (Form X)
Dimensions — See drawings on next
page
Weight — 4.58 oz (130g)
Electrical Data
Voltage Rating, Main Contacts
Switching (Max) — 750VDC
Current Rating, Main Contacts
Switching —
Continuous 1 — 100A
Short Term, 3 Minutes 2 — 200A
Contact Voltage Drop, Main
Contacts — 0.05 max @ rated current
Resistive Load Performance
(polarity sensitive) —
50A make/break @ +400Vdc —
50,000 cycles
50A make/break @ +600Vdc —
25,000 cycles
100A make/break @ +400Vdc —
6,000 cycles
100A make/break @ +600Vdc —
5,000 cycles
100A make/break @ -400Vdc —
1,000 cycles
100A make/break @ -600Vdc —
25 cycles
200A make/break @ +400Vdc —
500 cycles
200A make/break @ +600Vdc —
200 cycles
1,000A break only @ +400Vdc —
5 cycles
600A break only @ +600Vdc — 5 cycles
600A make only — 10 cycles
Maximum Short Circuit Current
(1/2 cycle, 60 Hz) — 1,250A
(through closed contacts)
Dielectric Withstand Voltage —
Between Open Contacts — 2,2000Vrms
Contacts to Coil — 1,500Vrms/4,000Vdc
Insulation Resistance, Terminal to
Terminal / Terminals to Coil —
When New — 100 megohms, min.
@ 500Vdc
At End of Life — 50 megohms, min.
@ 500Vdc
Mechanical Life — 106
Operate & Release Time
Operate Time Max. — 30ms
Operate Bounce Max. — 5ms
Release Time — 10ms
Environmental Data
Shock, 11ms 1/2 sine (operating)
— 20G peak
Sine Vibration, 20G peak —
55-2,000 Hz.
Operating Temperature Range —
-40°C to +85°C
Noise Emission (at 100 mm
distance) — 70dB(a)
Notes
1 8.4mm2 conductor. Current rating
is affected by conductor size.
Keep terminals below 150˚C max.
continuous.
2 3 minutes at +40˚C ambient, 1 min-
ute at –80˚C ambient with 8.4mm2
(#8 AWG) conductor.
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC EV100 Series (Continued)
Outline Dimensions
2 X (NOTE 1)
[4.57]
.18
2.12
[53.8]
[39.6]
1.56
1.82
[46.2]
.70
[17.8]
1.78
[45.2]
.30
[7.62]
1.71
[43.4]
1.49
[37.9]
LEAD LENGTH 15" +/-.5" [381 +/-12.7]
FROM TOP OF TERMINAL SEAT
NOTE 1. MOUNTING HARDWARE (NOT SUPPLIED)
2 X M4 BOLT, LOCKWASHER AND WASHER
TORQUE: 20 IN-LBS (2.3 NM) MAX
NOTE 2. LOAD TERMINALS-2 PLCS
HARDWARE NOT SUPPLIED
2 X M5 BOLT, LOCKWASHER AND WASHER
TORQUE: 30-40 IN-LBS (3.4 TO 4.5 NM)
DEPTH: 7 THREADS MAX
NOTE 2
Bottom Mount
1.77
[44.96]
1.53
[38.86]
Ordering Information
Typical Part Number EV100 A A A N A
Series:
EV100 = 100A, 600 Vdc Contactor
Contact Form:
A = Normally Open
Coil Voltage:
9-36 Vdc
Coil Wire Length:
A = 15 inches [.4M]
Coil Termination:
N = None – Stripped Wires
Mounting:
A = Bottom Mount 2X #8, M5X10 Mains
Specifications are subject to change without notice.
Coil Data (Internal Coil Economizer)
Coil Voltage Range 9-32 Vdc
Maximum Pickup Current (20˚C) 1.5A
Average Holding Current (20˚C) 0.25A@12Vdc/0.15A@24Vdc
Pickup Voltage (20C) ≥ 9Vdc
Dropout Voltage ≤ 8Vdc
Pickup Pulse (max.) 100 ms
Coil Resistance +/-5% (20˚C) 8.0 Ω
Coil Economizer Frequency 19.6 kHz
Coil Power Typ. (over temp range) 3-4W
KILOVAC High Voltage
DC Contactors
7
PAGE 43
KILOVAC High Voltage DC Contactors
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC LEV100 Series 900 Vdc Contactor
With 1 Form X Contacts Rated 100A Continuous
Product Facts
n Hermetically sealed —
Operates in explosive/
harsh environments without
oxidation or contamination
of contacts, including long
periods of non-operation
n 8kV isolation between
open contacts permits use
for high voltage isolation
and carry
n 12, 24 and 48 Vdc coils
n Designed and built in
accordance to AIAG QS9000
n Not position sensitive,
can be mounted in any
orientation
n Solid copper contacts
n UL Recognized
for the U.S. and
Canada (File
E208033)
All contact ratings & coil
versions may not be UL
Recognized
n RoHS versions available
Description
Lowest cost, 900 Vdc 100
amp, hermetically sealed
DC contactor in the industry
Compact package available
in side- or bottom-mount
configurations, not position
sensitive
Applications
Power/motor control circuit
isolation, circuit protection
and safety in industrial
machinery
Automotive battery
switching and backup
Mechanical
Compact epoxy-sealed resin
enclosure occupies only
about 4 in3 (65.5 cm3)
Robust integral mounting
plate on either bottom or
side of enclosure
accepts two M4 screws
Inert gas filled contact
chamber
Flying leads for coil connec-
tions
Load terminals threaded for
M5 bolts (not included)
Performance Data
Physical Data
Contact Arrangement, Main
Contacts — SPST-NO-DM (1 Form X)
Dimensions — See drawings on next
page
Weight — 6.7 oz (190g)
Contact Data
Contact Arrangement, Main
Contacts — SPST-NO-DM (1 Form X)
Voltage Rating, Main Contacts
Switching (Max) — 900VDC
Current Rating, Main Contacts
Switching —
Continuous 1 — 100A
Short Term, 3 Minutes 2 — 200A
Hot Switching Performance
(Polarity Sensitive) —
50A make/break @ +400Vdc — 50,000
cycles
100A make/break @ +400Vdc — 6,000
cycles
100A make/break @ -400Vdc — 1,000
cycles
200A make/break @ +400Vdc — 500
cycles
1,000A break only @ +400Vdc — 250
cycles
600A make only — 25 cycles
Maximum Short Circuit Current
(1/2 cycle, 60 Hz) — 1,250A
(through closed contacts)
Dielectric Withstand Voltage 3 —
Between Open Contacts —
5,600Vrms/8,000Vdc
Contacts to Coil —
2,000Vrms/4,000Vdc
Insulation Resistance, Terminal to
Terminal / Terminals to Coil —
When New — 100 megohms, min. @
500Vdc
At End of Life — 50 megohms, min. @
500Vdc
Mechanical Life — 1 million cycles
Operate & Release Time
Operate Time Max. — 25ms
Operate Bounce Max. — 5ms
Release Time — 10ms
Environmental Data
Shock, 11ms 1/2 sine
(operating) — 20G peak
Sine Vibration, 20G peak —
55-2,000 Hz.
Operating Temperature Range —
-40°C to +85°C
Noise Emission (at 100 mm
distance) — 70dB(a)
Notes
1 8.4 mm2 conductor. Current rating
depends upon conductor size.
Keep terminals below 175°C max
continuous.
2 3 minutes at +40°C ambient with
8.4 mm2 (#8 AWG) conductor.
3 2,000Vrms minimum under all con-
ditions, until end of life.
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC LEV100 Series 900 Vdc Contactor (Continued)
Ordering Information
Typical Part Number LEV100 A 4 A N G
Series:
LEV100 = 100A Contactor
Contact Arrangement:
A = 1 Form X (SPST-NO-DM)
Coil Voltage:
4 = 12VDC
5 = 24VDC
6 = 48VDC
Coil Wire Length:
A = 15 inches [.4M]
Coil Termination:
N = None – Stripped Wires
Mounting and Power Terminals:
G = Bottom Mount (2 x #8); M5 x 10
H = Side Mount (2 x #8); M5 x 10
Coil Operating Voltage (Valid Over Temperature Range)
Nominal Voltage 12Vdc 24Vdc 48Vdc
Maximum Voltage 16Vdc 28Vdc 52Vdc
Pick Up Voltage (20°C) 8Vdc 16Vdc 33Vdc
Drop Out Voltage (20°C) ≤1.2Vdc ≤2.4Vdc ≤4.8Vdc
Coil Current (Nominal at 20°C, 12vdc) 461mA 250mA 122mA
Coil Power
Nominal @ Vnom, +20°C 5.5W 6.0W 6.0W
Pickup (Close)
Voltage Max.@85˚C 9.6Vdc 19.2Vdc 38.4Vdc
Coil Resistance
Nominal @ +20°C ± 5% (ohms) 26 96 392
Life Cycles vs Resistive Load up to 900Vdc
Cycles (Make/Break)
Resistive Load, kW
1000000
100000
10000
1000
0102030405060708
09
0
KILOVAC High Voltage
DC Contactors
7
PAGE 45
KILOVAC High Voltage DC Contactors
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC LEV100 Series 900 Vdc Contactor (Continued)
MOUNTING HARDWARE (NOT SUPPLIED):
2 X M4 BOLT, LOCKWASHER AND WASHER
TORQUE: 20 IN-LBS MAX [2.3 NM MAX]
M5 FEMALE LOAD TERMINALS - 2 PLACES
HARDWARE (NOT SUPPLIED)
2 X M5 BOLT, LOCKWASHER AND WASHER
TORQUE: 30 TO 40 IN-LBS [3.4 TO 4.5 NM]
2.07
[ 52.52 ]
2.28
[57.96 ]
.30
[7.62 ]
.70
[17. 78 ]
1. 82
[ 46.3 ]
1.56 DIA.
[ 39.5 ]
M5 FEMALE LOAD TERMINALS - 2 PLACES
HARDWARE (NOT SUPPLIED)
2 X M5 BOLT, LOCKWASHER AND WASHER
TORQUE: 30 TO 40 IN-LBS [3.4 TO 4.5 NM]
MOUNTING HARDWARE (NOT SUPPLIED):
2 X M4 BOLT, LOCKWASHER AND WASHER
TORQUE: 20 IN-LBS MAX [2.3 NM MAX]
.83
[21.02 ]
1.61
[ 40.77 ]
.30
[7.62 ]
.70
[17. 78 ]
1. 82
[ 46.32 ]
2.07
[ 52.52 ]
.99
[ 25.04 ]
1.56 DIA.
[ 39.5 ]
2.28
[57.96 ]
Bottom Mount
Side Mount
Product Offering
Bottom Mount Models
3-1618389-7 LEV100A4ANG 12Vdc coil 15” [.4m] leads
9-1618389-8 LEV100A5ANG 24Vdc coil 15” [.4m] leads
3-1618391-7 LEV100A6ANG 48Vdc coil 15” [.4m] leads
Side Mount Models
4-1618391-0 LEV100A4ANH 12Vdc coil 15” [.4m] leads
4-1618391-1 LEV100A5ANH 24Vdc coil 15” [.4m] leads
4-1618391-2 LEV100A6ANH 48Vdc coil 15” [.4m] leads
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
KILOVAC LEV100H High-Voltage Contactor
Product Facts
n Safe for application in
harsh, explosive, and
corrosive environments
n No contact oxidation over
periods of non-use
n Not position sensitive;
available in side and bottom
mount configurations
n 8 kV isolation between open
contacts permits use for
high voltage isolation and
carry
n 12, 24, and 48 VDC coils
available
n Small 1000 VDC, 150 A
contactor
Applications
n Energy Storage/Battery
Storage
n Power Distribution
n Alternative Energy
n Hybrid Electric Vehicles
(Military and Commercial)
n Test Equipment
Description
The new KILOVAC
LEV100H extended
performance contactors
with auxiliary contacts
from TE Connectivity (TE)
are designed for harsh
environment and load
applications. This version
of our popular EV and LEV
series contactors offers
extremely high performance
for its small size and low
weight. Hermetically sealed,
KILOVAC LEV100H
contactors are capable of
operating in harsh, explo-
sive environments without
oxidation or contamination
of contacts, even after long
periods of non-operation.
Mechanical/Environmental
Contact Arrangement —
Main Contacts — SPST-NO (Form X)
Auxiliary Contact — SPST-NO (Form
A) (Note 1)
Dimensions — See drawings
Weight — 6.70 oz. (190 g)
Hermetically Sealed
Safe for Harsh/Corrosive
Environments
Contact Oxidation — None over
periods of non-use
Shock — 11 ms 1/2 sine (operating,
20 g Peak)
Sine Vibration — 20 g peak—
55-2000 Hz
Operating Temperature Range—
40°C to +80°C
Noise Emission (at 100 mm distance)
— 70 dBa
Electrical Data
Mechanical Life — 1,000,000 cycles
Voltage Rating —
Main Contacts Switching (max.) —
1000 VDC
Continuous (Note 2) 100 A
Short Term (3 minutes) (Note 3)—
200 A
Contact Voltage Drop — Main
Contacts: 0.05 max. @ rated current
Resistive Load Performance
(polarity sensitive) —
50 A make/break @ +1000 VDC—
50 cycles
100 A make/break @ +400 VDC—
1000 cycles
200 A make/break @ +400 VDC—
500 cycles
1000 A break only @ +400 VDC—
2 cycles
600 A make only: 10 cycles
50 A @ 400 VDC make only—
25,000 cycles
Maximum Short Circuit Current
(1/2 cycle, 60 Hz) (through closed
contacts) — 1250 A
Dielectric Withstanding Voltage —
Between Open Contacts (Note 4) —
5600 Vrms
Contacts to Coil — 2200 Vrms
Insulation Resistance @ 500 VDC,
Terminal to Terminal/
Terminals to Coil —
New — 100 MΩ min.
End of Life — 50 MΩ min.
KILOVAC High Voltage
DC Contactors
7
PAGE 47
KILOVAC High Voltage DC Contactors
KILOVAC LEV100H High-Voltage Contactor (Continued)
PART drawing
C
B
D
LABEL
MOUNTING HARDWARE (NOT SUPPLIED)
2 X M4 BOLT, LOCKWASHER AND WASHER
TORQUE: 20 IN-LBS MAX [2.3 NM MAX]
M5 FEMALE LOAD TERMINALS - 2 PLACES
HARDWARE (NOT SUPPLIED)
2 X M5 BOLT, LOCKWASHER AND WASHER
TORQUE: 30 TO 40 IN-LBS [3.4 TO 4.5 NM]
53.85
[2.12]
40.89
[1.61]
21.08
[.83]
17.78
[.701]
52.58
[2.07]
46.23
[1.82]
25.15
[.99]
C
B
D
52.58
[2.07]
COIL LEADS: BLACK
AUX LEADS: RED
7.62
[.30]
Ø
39.62
[
Ø
1.56]
17.78
[.70]
46.23
[1.82]
53.85
[2.12]
LABEL
Coil Voltage, Nominal/Max. 12/16 VDC 24/28 VDC 48/52 VDC
Coil Resistance (20°C) 26 Ω96 Ω392 Ω
Pick Up Voltage (20°C) 8 VDC 16 VDC 33 VDC
Dropout Voltage (20°C) ≤1.2 VDC ≤2.4 VDC ≤4.8 VDC
Coil Current (Nom. at 20°C, 12 VDC) 0.46 A 0.25 A 0.12 A
Coil Power (Nom. at Vnom, 20°C) 5.5 6.0 6.0
Main
Contacts:
Operate Time (Max.) 25 ms
Operate Bounce (Max.) 6 ms
Release Time 10 ms
Operate and Release Time
Typical Part Number LEV100 H 5 C N G
Series:
LEV100 = 1000 VDC, 150 A Contactor
Contact Form:
H = NO with 1PST NO Aux
Coil Voltage:
4 = 12 VDC
5 = 24 VDC
6 = 48 VDC
Coil Wire Length:
C = 10˝ [.25 m]
Coil Termination:
N = None – Stripped Wires
Mounting :
G = Bottom Mount, 2 x #8, M5 x 10 Mains H = Side Mount, 2 x #8, M5 x 10 Mains
Schematic
+A1
–A2
+X1
–X2
B1
B2
(HVDC POWER)
(COIL)
(AUXILIARY)
Note: Contactors should be
installed so that current flows
from A1 (+) to A2 (-)
KILOVAC High Voltage DC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
Ordering Information
Typical Part Number LEV200 A 4 N A A
Series:
LEV200 = 500+ Amp, 12-900Vdc Contactor
Contact Form:
A = Normally Open
H = Normally Open with Aux. Contacts. (Option
“H” requires option “A” in Coil Wire Length
and option “N” in Coil Terminal Connector.)
Note: Other auxiliary contact forms available.
Consult factory.
Coil Voltage:
4 = 12Vdc 5 = 24Vdc B = 28Vdc
6 = 48Vdc K = 72Vdc
8 = 96Vdc L = 110Vdc O = 115Vac 9 = 240Vac
Notes: Consult factory for detailed specifications
and availability of coils not listed in
“Coil Data” table above. In coil voltage
codes, 115Vac is designated by the
letter “O” rather than the numeral “0.”
Coil Wire Length:
A = 15.3 in (390 mm) N = None (Requires option
“A” in next step.)
Coil Terminal Connector:
N = None, stripped wires
(Requires option “A” in previous step.)
A = Studs, #10-32 Threaded (Electrical connection
is made to the tab at the base of the stud.)
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
Consult factory regarding other available mountings and
power terminals.
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC LEV200 Series Contactor With 1 Form X
Contacts Rated 500+ Amps, 12-900Vdc
Performance Data
Contact Arrangement, Power
Contacts — 1 Form X (SPST-NO-DM)
Rated Operating Voltage —
12 - 900 VDC
Continuous (Carry) Current,
Typical — 500 A @ 65°C, 400 mcm
conductors
Consult TE for required conductors
for higher (500+ A) currents
Make/Break Current at Various
Voltages 1 — See graph next page
Break Current at 320VDC 1 —
2,000 A, 1 cycle 3
Contact Resistance, Typ.
(@200A) — 0.2 mohms
Load Life — See graph next page
Mechanical Life — 1 million cycles
Contact Arrangement, Auxiliary
Contacts — 1 Form A (SPST-NO)
Aux. Contact Current, Max. —
2A @ 30VDC / 3A @ 125VAC
Aux. Contact Current, Min. —
100mA @ 8V
Aux. Contact Resistance, Max. —
0.417 ohms @ 30VDC /
.150 ohms @ 125VAC
Operate Time @ 25°C —
Close (includes bounce), Typ. — 25 ms
Bounce (after close only), Max. — 7 ms
Release (includes arcing), Max @
2000A — 12 ms
Dielectric Withstanding Voltage —
2,200 Vrms @ sea level (leakage <1mA)
Insulation Resistance @ 500VDC —
100 megohms 2
Shock, 11ms 1/2 Sine, Peak,
Operating — 20 G
Vibration, Sine, 80-2000Hz.,
Peak — 20 G
Operating Ambient Temperature
—
-40°C to +85°C
Weight, Typical — 1.3 lb. (.60 kg)
Notes:
1 Main power contacts
2 50 at end of life
3 Does not meet dielectric & IR after
test, 1700 amp for unit with Aux.
Contacts
4 Contacts will operate with 0.8Vnom
< Vcoil < 1.1Vnom over temperature
Coil Data (Valid Over Temperature Range) 4
Nominal Voltage 12Vdc 24Vdc 48Vdc
Pickup Voltage (Will Operate) 9.0Vdc 19.0Vdc 38.0Vdc
Voltage (Max.) 15Vdc 30Vdc 60Vdc
Dropout Voltage 0.75 - 2.0Vdc 1.0 - 5.0Vdc 2.0 - 7.0Vdc
Coil Resistance @ 25° (Typ.) 11 ohms 40 ohms 145 ohms
Product Facts
n Designed to be the lowest
cost sealed contactor in
the industry with its current
rating (500+A carry, 2000A
interrupt at 320Vdc)
n Available with bottom
or side mounting — not
position sensitive
n Optional auxiliary contact
for easy monitoring of
power contact position
n Hermetically sealed —
operates in explosive/
harsh environments with no
oxidation or contamination
of coils or contacts,
including long periods of
non-operation
n Typical applications include
battery switching and
backup, DC voltage power
control, circuit protection
and safety
n Versatile coil/power
connections
n Designed and built in
accordance to AIAG QS9000
n RoHS compliant
Invalid
Combinations/Reason
LEV200H-NA_
No auxiliary function with coil
studs
LEV200_ONA_
No coil studs with rectifier circuit
LEV200_9NA_
No coil studs with rectifier circuit
LEV200_O_F
No side mont with rectifier circuit
LEV200_9_F
No side mount with rectifier circuit
KILOVAC High Voltage
DC Contactors
7
PAGE 49
KILOVAC High Voltage DC Contactors
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC LEV200 Series (Continued)
Outline Dimensions
Estimated Make & Break Power Switching Ratings
NOTES:
1) For resistive loads with 300µH 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.
100,000
10,000
1,000
100
10
11,000 10,000
100101
Make and Break Power Switching Region Break Only Above 650A
650A
Estimated Life (Cycles)
Load Current (A)
1800 VDC
900 VDC
600 VDC
400 VDC
270 VDC
120 VDC
28 VDC
Time (ms)
Current (A)
LEV200 Capacitive Make Test Curves for Pre-Charged Motor Controller
650
600
550
500
450
400
350
300
250
200
150
100
50
0
0.0 0.5 1.0 1.5 2.0
80% Minimum
Pre Charge
90% Nominal
Pre Charge
700
SIde Mount Enclosure
Bottom Mount Enclosure
Note: When stud terminals are
specified for coil connections,
the electrical connection is
made at the tab located at the
base of the stud.
KILOVAC High Voltage AC Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
FM200 (“Flatman III”) Series Contactor
200 Amps, 480 VAC (50/60 Hz), or 48 Vdc, 1-, 2-, or 3-poles
Product Facts
n Multi-pole configurations
n Normally open, normally
closed and mixed contact
arrangements
n Optional quick connect tabs
for sensing
n Small, lightweight & cost-
effective – designed to be
the smallest, lowest cost
contactor in the industry with
its current rating
n Standard models available
with 12VDC, 24VDC and 115
VAC coils. Consult factory for
240VAC coil models.
n 1 Form A auxiliary contacts
Available Pole Configurations and Applicable Coil Codes
No. of NC Poles (across) 0 1 2 3
No. of NO Poles (down)
0 Y YY YYY
Coil D Coil D Coil D
1 X XY YXY
Coil A/B/C/E Coil A/B/C/E Coil D
2 XX XYX
Coil A/B/C/E Coil A/B/C/E
3 XXX
Coil A/B/C/E
X = Form X (NO-DM) Y = Form Y (NC-DB)
Coil Operating Voltage (valid over temperature range)
Coil Designator Units A B C D
Nominal Voltage V 12 (DC) 24 (DC) 115 (AC) 24 (DC)
Voltage Range V 9.6-13.2 19.2-26.4 92-126.5 19.2-
26.4
Hold Voltage V ≥0.5Vnom ≥0.5Vnom ≥0.5Vnom ≥0.5Vnom
Dropout Voltage V ≤0.1Vnom ≤0.1Vnom ≤0.1Vnom ≤0.2Vnom
Coil Resistance Data for Pole Configurations (@25°C)
Coil Designator Units A B* C* D*
Resistance ±10% Ohms X = 36 X = 36 X = 36 Y = 20.8
XX = 18 XX = 18 XX = 18 YY = 10.4
XXX = 12 XXX = 12 XXX = 12 YYY = 6.9
XY = 13.2 XY = 13.2 XY = 13.2 YXY = 8.1
XYX = 9.6 XYX = 9.6 XYX = 9.6
*Coil resistance not measurable at terminals due to converter/economizer circuit.
Coil Current/Power Data for Pole Configurations (@25°C, Vcoil=1.1Vnom)
Coil Designator A B**
Current/Power X = 0.37 ADC / 4.84W X = 0.33ADC / 3.9W
XX = 0.73ADC / 9.68W XX = 0.65ADC / 7.6W
XXX = 1.1ADC / 14.5W XXX = 0.97ADC / 11.3W
XY = 1.0ADC / 13.2W XY = 0.98ADC / 12.7W
XYX = 1.38ADC / 18.2W XYX = 1.31ADC / 16.5W
Coil Designator C D*** Pick-Up I / Duration
Current/Power X = 0.067 Arms / 6.8VA Y = 0.13ADC / 3.4W 1.28ADC / 75ms
XX = 0.115Arms / 11.6VA YY = 0.23ADC / 6.1W 2.4ADC / 75ms
XXX = 0.146Arms / 14.8VA YYY = 0.34ADC / 9.0W 3.0ADC / 75ms
XY = 0.074Arms / 7.5VA YXY = 0.28ADC / 7.4W 3.0ADC / 75ms
XYX = 0.161Arms / 16.3VA
**Average coil current. ***Economized.
Operate/Release Time (25°C, 0.8Vnom ≤ V < Vnom) Typ.
Coil Designator Units A B**** C**** D****
Operate Time ms 25-50 30-50 50-150 20-30
Release Time ms 10-20 70-80 75-100 75-100
Bounce Time ms 2-5 2-5 2-5 2-5
****Includes internal coil suppression.
File E208033
Product Specifications
Parameter Units Value for FM200 Series
Contact Arrangement 1, 2 or 3 poles
Contact Form (per pole) Form X or Y (NO-DM or NC-DB)
Rated Operating Voltage V 480Vrms (L-L) or 48VDC
Max. Contact Voltage (transient) V 750Vrms or 60VDC
Continuous (Carry) Current Arms or ADC 200/pole (Form X)
150/pole (Form Y)
Power Switching Form X (0.7-1.0 PF) Cycles 2,000 @ 300Arms
10,000@ 200Arms
20,000 @ 100Arms
5,000 @ 200A/48VDC
2 million @ 50A/28VDC
Power Switching Form Y (0.7-1.0 PF) Cycles 2,000 @ 225Arms
10,000@ 150Arms
20,000 @ 75Arms
5,000 @ 150A/48VDC
2 million @ 35A/28VDC
Mechanical Life Cycles >2 million
Contact Voltage Drop mV 75 for Form X or Form Y
Auxiliary Contact Arrangement 1 Form A (SPST-NO)
Auxiliary Contact Rating Arms or ADC 1 @ 30VDC, 3 @ 125VAC
Dielectric Withstanding Voltage Vrms 2,200 @ sea level
Insulation Resistance @ 500VDC Megohms 100
Shock, 11ms 1/2 sine, peak G 10
Vibration, sine, 10-2000Hz. G 5
Operating Temperature °C -20 to +60
Storage Temperature °C -40 to +85
Ambient Humidity %RH 0 to 95
Weight oz. / kg 17.6 - 49.4 / 0.5 -1.4
See Outline Dimensions for model-specific weight information.
KILOVAC High Voltage
AC Contactors
7
PAGE 51
KILOVAC High Voltage AC Contactors
FM200 “Flatman III” Series Contactor (Continued)
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
MAIN TERMINAL
WIRE CONNECT
VIA M8 BOLT W/LOCK/FLAT
13MM (0.5 IN) HEX HEAD
3.77
(95.8)
1.22
(31.0)
C
A
B
3.77
(95.8)
3.42
(86.9)
2.74
(69.6)
2.98
(75.7)
.256 DIA.
(6.5)
RIGHT ANGLE SCREW
TERMINAL STRIP
ACCEPTS
#24 - #14 WIRE
4.2
(106.7)
2.29
(58.2) 1.93
(49.0)
2.29
(58.2)
1.86
(47.2)
.40
(10.2)
OPTIONAL TA B
TERMINALS
.250 x .032
(6.35 x .813)
NUMBER OF POLES
DIM.
A
B
C
123
1.68
(42.7)
2.67
(67.7)
3.65
(92.7)
2.14
(54.3)
3.12
(79.3)
4.11
(104.4)
1.56
(39.6)
2.55
(64.6)
3.53
(89.7)
WEIGHT 17.6 oz.
(0.5 kg)
35.3 oz.
(1.0 kg)
49.4 oz.
(1.4 kg)
Outline Dimensions
Part Numbering System
Typical Part Number FM200 A B XYX
Series:
FM200 = Multipole, 200 Amp, 480VAC/48VDC Contactor
Control Voltage:
A = 12VDC Coil, No Suppression
B = 24VDC Converter, with Suppression
C = 115VAC Converter, with Suppression
D = 24VDC Electronic Chopper, with Suppression
E = 240VAC Converter, with Suppression - Consult Factory for Availability and Specifications
Optional Termination:
A = Optional Quick Connect Tabs
B = No Optional Terminals
Pole Configuration (All models have a 1 Form A (SPST-NO) auxiliary switch):
X = 1 Form X (SPST-NO-DM), Available with control voltage codes A, B, C and E
XX = 2 Form X (2PST-NO-DM), Available with control voltage codes A, B, C and E
XXX = 3 Form X (3PST-NO-DM), Available with control voltage codes A, B, C and E
Y = 1 Form Y (SPST-NC-DB), Available only with control voltage code D
YY = 2 Form Y (DPST-NC-DB), Available only with control voltage code D
YYY = 3 Form Y (3PST-NC-DB), Available only with control voltage code D
XY = 1 Form X (SPST-NO-DM) + 1 Form Y (SPST-NC-DB), Available with control voltage codes A, B, C and E
XYX = 1 Form X (SPST-NO-DM) + 1 Form Y (SPST-NC-DB) + 1 Form X (SPST-NO-DM), Available with control voltage codes A, B, C and E
YXY = 1 Form Y (SPST-NC-DB) + 1 Form X (SPST-NO-DM) + 1 Form Y (SPST-NC-DB), Available only with control voltage code D
KILOVAC 270+ Vdc Traditional Aerospace Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
AP90X-05 - 90 Amps SPUD Contactor
Product Facts
n 90 A carry, 350 A overload
@ 270 Vdc
n Same size and weight as
AP50X
n Versatile power, voltage,
and current operating range
n Ideal for circuit protection
and control
n Bi-directional switching
n Fast operate and release
time
n Low power consumption
n Vacuum-sealed contacts;
can operate in harsh
environments
n Space-rated version built in
accordance with customers
SCD
n Meets many requirements
of MIL-PRF-32085
Product Specifications
Contact Arrangement —
SPST-NO
Contact Form — X
Rated Resistive Load @ 270 Vdc
— 90 A
Continuous Current Carry, Max.
— 65 A
Overload @ 270 Vdc — 350 A
Contact Resistance, Max. —
2 mohm
Dielectric at Sea Level —
Coil to Power Terminals — 1,800 Vrms
All Other Points — 2,000 Vrms
Shock, 11ms, 1/2 Sine (Peak) —
30 g
Vibration, Sinusoidal
(55-2000 Hz, Peak) — 20 g
Operating Ambient Temperature
Range — -55°C to +90°C
Load Life @ 270 Vdc, Min. —
25,000 cycles
Operate Time,
Excluding Bounce, Max. — 35 ms
Release Time, Max. — 10 ms
Bounce Time, Max. — 8 ms
Insulation Resistance @ 500 Vdc,
Min. —
Initial — 100 mohm
End of Life — 50 mohm
Weight, Nominal —
454 gram (16 oz.)
Coil Data
Volts, Nominal 12 28 120
Pickup, Max. 9.9 Vdc 23 Vdc 99 Vdc
Dropout, Min. .4 Vdc 1.0 Vdc 4.0 Vdc
Coil Resistance (±10%) 19 Ω 103 Ω 1890 Ω
Energy, Magnetic, Max. .05 J .05 J .05 J
Coil resistance rated at 25°C
Contact Ratings*
* Based on data extrapolated from qualification at 270 Vdc with resistive load.
Since each application is unique, user is encouraged to verify rating in actual
application.
KILOVAC 270+ Vdc
Traditional Contactors
7
PAGE 53
KILOVAC 270+ Vdc Traditional Aerospace Contactors
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
AP90X - 90 Amps SPUD Contactor
Product Facts
n 90 A carry, 350 A overload
@ 270 Vdc
n Same size and weight as
AP50X
n Versatile power, voltage,
and current operating range
n Ideal for circuit protection
and control
n Bi-directional switching
n Fast operate and release
time
n Low power consumption
n Vacuum-sealed contacts;
can operate in harsh
environments
n Space-rated version built in
accordance with customers
SCD
n Meets many requirements
of MIL-PRF-32085
Product Specifications
Contact Arrangement —
SPST-NO
Contact Form — X
Rated Resistive Load @ 270 Vdc
— 90 A
Continuous Current Carry, Max.
— 90 A
Overload @ 270 Vdc — 350 A
Contact Resistance, Max. —
2 mohm
Dielectric at Sea Level —
Coil to Power Terminals — 1,800 Vrms
All Other Points — 2,000 Vrms
Shock, 11ms, 1/2 Sine (Peak) —
30 g
Vibration, Sinusoidal
(55-2000 Hz, Peak) — 20 g
Operating Ambient Temperature
Range — -55°C to +85°C
Load Life @ 270 Vdc, Min. —
25,000 cycles
Operate Time,
Excluding Bounce, Max. — 27 ms
Release Time, Max. — 10 ms
Bounce Time, Max. — 8 ms
Insulation Resistance @ 500 Vdc,
Min. —
Initial — 100 mohm
End of Life — 50 mohm
Weight, Nominal —
454 gram (16 oz.)
Coil Data
Volts, Nominal 12 28 120
Pickup, Max. 9.9 Vdc 23 Vdc 99 Vdc
Dropout, Min. .4 Vdc 1.0 Vdc 4.0 Vdc
Coil Resistance (±10%) 19 Ω 103 Ω 1890 Ω
Energy, Magnetic, Max. .05 J .05 J .05 J
Coil resistance rated at 25°C
Contact Ratings*
* Based on data extrapolated from qualification at 270 Vdc with resistive load.
Since each application is unique, user is encouraged to verify rating in actual
application.
Ordering Information
Sample Part Number AP90 X B 5 7
Series:
Contact Form:
X = SPST-NO Double Make
Coil Voltage:
A = 12 Vdc, Stud Terminals
B = 28 Vdc, Stud Terminals
C = 120 Vdc, Stud Terminals
Power Terminals:
5 = Stud Terminals
Mounting:
7 = Panel Mount
KILOVAC 270+ Vdc Traditional Aerospace Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
Ordering Information
Sample Part Number AP150 X B 5 7
Series:
Contact Form:
X = SPST-NO Electrically Held
Coil Voltage:
A = 12 Vdc, Stud Terminals, .138-32
B = 28 Vdc, Stud Terminals, .138-32
C = 120 Vdc, Stud Terminals, .138-32
Power Terminals:
5 = Stud Terminals, .375-24
Mounting:
7 = Panel Mount
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
AP150X (Form X, Electrically Held)
CZONKA Contactor
Product Facts
n 150 A carry, 500 A overload
@ 270 Vdc
n Suitable for circuit
protection, control, and
battery switching
n Versatile power, voltage,
and current operating range
n Bi-directional switching
n Electrically held and
latching coil versions
n Fast operate and release
time
n Low power consumption
n Vacuum-sealed contacts;
can operate in harsh
environments
n Space-rated version built in
accordance with customers
SCD
n Meets many requirements
of MIL-PRF-32085
Product Specifications
Contact Arrangement —
AP150X — SPST-NO
Contact Form —
AP150X — X
Rated Resistive Load @ 270 Vdc
— 150 A
Continuous Current Carry, Max.
— 150 A
Overload Make & Break @
270 Vdc — 400/500 A*
Contact Resistance, Max. —
1 mohm
Dielectric at Sea Level —
Power Terminals to Terminal —
2,000 Vrms
Power Terminals to All Other Points —
1,800 Vrms
Shock, 11ms, 1/2 Sine (Peak) —
35 g
Vibration, Sinusoidal
(55-2000 Hz, Peak) — 20 g
Operating Ambient Temperature
Range — -55°C to +85°C
Load Life @ 270 Vdc, Min. —
10,000 cycles
Operate Time (28 Vdc, 25°C) —
Close (Includes Bounce), Typ. —
AP150X — 35 ms
Bounce (After Close Only), Max. —
AP150X — 8 ms
Open (Includes Arcing), Max. —
AP150X — 10 ms
Insulation Resistance @ 500 Vdc,
Min. — Initial/End of Life — 100
mohm/50 mohm
Weight, Nominal —
1.66 lb (0.753 kg)
Note:
* 500 = at beginning of life which is 0
to 5,000 cycles, 400 = at end of life
which is 5,000 to 10,000 cycles.
Coil Data
AP150X AP150P
Voltage, Nominal* 28 Vdc 28 Vdc
Pickup (Close), Max. 23 Vdc 20 Vdc
Dropout (Open), Max. 1.0 Vdc 20 Vdc
Coil Resistance @ 25°C (10%) 52 Ω 13 Ω**
Coil Duty, Recommended Continuous 100 ms to Toggle
Coil Energy, Max. 0.10 J 0.10 J
Coil Clamping 2.5 x nom. 500W/ms TVS
*12, 120 Vdc, or other special coil voltages available upon request.
** 2 coils are used, both are high common. Switch coil power from low side.
High side coil power switch is a special order.
Contact Ratings*
* Based on data extrapolated from qualification at 270 Vdc with resistive load.
Since each application is unique, user is encouraged to verify rating in actual
application.
KILOVAC 270+ Vdc
Traditional Contactors
7
PAGE 55
KILOVAC 270+ Vdc Traditional Aerospace Contactors
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
AP265 (Form X, Electrically Held) & AP265P (Form P, Latching) 265 Amps
CZONKA II Contactor
Product Facts
n 265 A carry, 1000 A
overload @ 270 Vdc
n Bi-directional power
switching
n Auxiliary Contacts
n Electrically held and
latching coil versions
n Built-in coil drivers for
electrically held (5W hold)
and latching (coil pulser)
n Coil divers EMC qualified to
most of the requirements of
MIL-STD-461D
n Versatile power, voltage,
and current operating range
n Excellent for safety
disconnect and transfer
switch applications
n Designed for main generator
loads
n Suitable for circuit
protection and control
n Remote Power Controller
version with overload
protection available —
contact factory for more
information
n Hermetically-sealed
contacts; can operate in
harsh environments
n Space-rated version built in
accordance with customers
SCD
n Meets many requirements
of MIL-PRF-32085
Product Specifications
Contact Arrangement Mains —
AP265X — Form X — SPST-NO
Form A — 2 x SPST-NO
AP265P — Form X — SPST
Form A — 2 x SPST
Polarity (Carry and Switching) —
Bi-directional
Rated Resistive Load @ 270 Vdc
— 265 A
Continuous Current Carry, Max.
— 265 A
Overload Current @ 270 Vdc,
Max. —
Make and Break — 600 A
Break Only — 1000 A
Contact Resistance, Max. —
0.3 mohm
Dielectric at Sea Level
(< 1 mA leakage) —
Power Terminals to Terminal —
1,000 Vrms
Power Terminals to All Other Points —
1,000 Vrms
Shock, 11ms, 1/2 Sine (Peak) —
25 g
Vibration, Sinusoidal
(55-2000 Hz, Peak) — 10 g
Operating Ambient Temperature
Range — -55°C to +85°C
Load Life @ 270 Vdc, Min. —
See graph above
Operate Time (28 Vdc, 25°C) —
Close (Includes Bounce), Typ. —
AP265X — 20 ms
AP265P — 10 ms
Bounce (After Close Only), Max.
— 5 ms
Open (Includes Arcing), Max. —
15 ms
Insulation Resistance @ 500 Vdc,
Min. —
Initial/End of Life — 100 mohm/50 mohm
Weight, Nominal —
1.7 lb (0.77 kg)
Ordering Information
Sample Part Number AP265 X E 9 7
Series:
Contact Form:
X = SPST-NO, Electrically Held
P = SPST, Latching
Coil Voltage:
E = 28 Vdc
Power Terminals:
9 = Female Threads, .250-20
Mounting:
7 = Panel Mount, Helcoil Locking
Coil Data
AP265X AP265P
Type Driver “PWM” Econ. Pulser
Voltage, Nominal 28 Vdc 28 Vdc
Pickup (Close), Max. 20 Vdc 12 Vdc
Dropout (Open), Max. 11 Vdc 12 Vdc
Current @ 28 V, 25°C
Inrush 1.8 A 2.6 A
Holding (Standby) 0.20 A <0.05 A
Inrush Time, Max. 100 ms 100 ms
Electrical Life Cycles vs Power Switching
KILOVAC 270+ Vdc Traditional Aerospace Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
AP350X “BUBBA” Contactor 500 Amps
Product Facts
n 500 A carry, 1200 A make,
3000 A break @ 270 Vdc
n Bi-directional power
switching
n Auxiliary Contacts
n Built-in coil power
economizing — 6 W holding
n Versatile power, voltage,
and current operating range
n Excellent for safety
disconnect and transfer
switch applications
n Suited for circuit protection
control
n Hermetically-sealed
contacts; can operate in
harsh environments
n Designed for main generator
loads
n Space-rated version built in
accordance with customers
SCD
n Meets many requirements
of MIL-PRF-32085
Product Specifications
Contact Arrangement with
Auxiliary Contact (28 Vdc, 0.1 A) —
Form X — SPST-NO
Form A — SPST-NO
Rated Resistive Load @ 270 Vdc,
85°C — 350 A
Continuous Current Carry, Max.,
25°C — 500 A
Overload Current @ 270 Vdc,
Max. —
Make (Closed Into) — 1200 A
Break (Open) — 3000 A
Contact Resistance, Max. —
0.2 mohm
Dielectric at Sea Level
(< 1mA leakage) —
Open Power Terminal to Terminal —
2,000 Vrms
Closed Power Terminals to All Other
Points — 2,000 Vrms
Shock, 11ms, 1/2 Sine (Peak) —
25 g
Vibration, Sinusoidal
(55-2000 Hz, Peak) — 10 g
Operating Ambient Temperature
Range — -55°C to +85°C
Load Life @ 270 Vdc, Min. —
See graph above
Operate Time @ 25°C —
Close (Includes Bounce), Typ. —
35 ms
Bounce (Occurs When Closing),
Max. — 5 ms
Open (Includes Arcing), Max. —
20 ms
Insulation Resistance @ 500 Vdc,
Min. —
Initial/End of Life — 100 mohm/50 mohm
Weight, Nominal —
3.35 lb (1.52 kg)
Coil Data
AP350X
Type Driver “PWM” Econ.
Voltage, Nominal 28 Vdc
Pickup (Close), Max. 20 Vdc
Dropout (Open), Max. 11 Vdc
Current @ 28 V, 25°C
Inrush 2.1 A
Holding (Standby) 0.21 A
Inrush Time, Max. 200 ms
Electrical Life Cycles vs Power Switching
* Failure mode: Dielectric withstand voltage test @ 2000 Vdc, power terminal
to terminal, leakage exceeds 1.0 A. Current Carry: 500 A @ 25°C. Derate
2.5 A/°C to 350 A @ 85°C for still air, no heat sink, AWG# 00 conductor.
Ordering Information
Sample Part Number AP350 X B 5 7
Series:
Contact Form:
X = SPST-NO Double Make
Coil Voltage:
B = 28 Vdc, Stud Terminals
Power Terminals:
5 = Screw Terminals
Mounting:
7 = Panel Mount, captive bolts
Refer to EV500 Sales Drawing for complete specifications.
KILOVAC 28 – 1800 Vdc
Traditional Contactors
7
PAGE 57
KILOVAC 28 – 1800 Vdc Traditional Contactors
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
EV250-1A & 1B 400 Amps CZONKA-II EVX Make & Break Load Switching
Product Facts
n Hydrogen dielectric for
power switching high
current loads
n 400 A carry, 2,500 A
interrupt @ 320 Vdc
n Suited for circuit protection,
control, battery switching,
and main power safety
disconnect
n Versatile power, voltage,
and current operating range:
28-1800 Vdc tested
n Low-cost compact version
for volume production
applications. Requires
external coil economizer
(PWM or lower hold
voltage)
n “Hammer effect”
mechanism breaks light
contact welds
n “Super-sealed”
environment chamber
uniquely protects ALL
moving parts
n Can operate in harsh
environments
n Moving contact rotates
to provide fresh contact
surface for low contact
resistance and low power
consumption
n Sealed control connector.
Mating connector with flying
leads Part Number 2005
available, see page 7-95
n Logic control enabled by
external economizer Part
Number 9913
n High temperature (135°C)
model with 10 inch flying
leads available (-4A — Call
TE for sales drawing)
n Bi-directional power
switching
n Fast operate and release
time
Product Specifications
Contact Arrangement — SPST-NO
Contact Form — X
Continuous Current Carry, Max. —
400 A; 6.5 Minutes — 500 A
Break Current @ 320 Vdc —
2,500 A
Contact Resistance, Max. —
0.0003 ohm
Contact Resistance, Typ. —
0.0001 – 0.0002 ohm
Dielectric at Sea Level
(Leakage < 1mA) — 2,200 Vrms
Shock, 11ms, 1/2 Sine (Peak),
Operating — 30 g
Vibration, Sinusoidal
(80-2000 Hz, Peak) — 20 g
Operating Ambient Temperature
Range — -40°C to +85°C
Load Life — See chart on next page
Operate Time, @ 25°C —
Close (Includes Bounce), Typ. —
30 ms
Bounce (After Close Only), Max.
— 5 ms
Open (Includes Arcing), Max. —
15 ms
Insulation Resistance @ 500 Vdc,
Min. — 100 mohm
Weight, Nominal —
1.54 lb (0.7 kg)
Ordering Information
Sample Part Number EV250-1 A
Series:
Coil Voltage:
A = 12 Vdc, Nominal
B = 24 Vdc, Nominal
For detailed specifications and recommendations, refer to the
EV250-1A & B sales drawings.
Coil Data***
EV250-1A EV250-1B
Voltage, Nominal* 12 Vdc 24 Vdc
Pickup (Close), Max. 8.3 Vdc 16.6 Vdc
Continuous Hold, Max./Min.** 5.1/3.8 Vdc 10.2/7.6 Vdc
Dropout (Open), Min. 0.88 - 3.3 Vdc 2.4 - 6.6 Vdc
Coil Resistance @ 25°C, ±10% 3 Ω 12 Ω
Coil Energy, Max. 0.2 J 0.2 J
Coil Clamping 3 x nom. 3 x nom.
* Do not apply continuously. Requires external coil economizer. Other spe-
cial coil voltages available upon request.
** At maximum continuous current and maximum ambient temperature. Hold
voltage must be maintained within the limits specified to keep contacts
closed and to prevent coil overheating.
*** Do not use a free wheeling diode or capacitor across the coil.
Note: Dimensions in inches. Multiply values by 25.4 for dimensions in mm.
Contact Ratings*
* 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.
KILOVAC 28 – 1800 Vdc Traditional Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
EV250-1A & 1B 400 Amps CZONKA-II EVX Make & Break Load Switching (Continued)
Life Ratings and Qualification Test Plan
Normal Operations Abnormal Operations
Test # 1 2 3 4
Current Reference Graph and -250 A 2500 A
Voltage Test Circuit Diagram (Sht. 8) 320 V 320 V
Load Type Capacitive Capacitive Resistive Resistive
% Pre Charge 90% 70% NA N/A
Switch Mode Make Only Make Only Make/Break Break Only
Sequence
1 10K cycles 10 cycles 2 2
2 10K 10 2 —
3 10K 10 2 —
4 10K 10 2 2
5 10K 10 2 —
Etc. Continue Cycling to Relay Failure
The testing objective is to verify proper relay function for a given number of consecutive and cumulative cycles under
both normal and abnormal conditions in a variety of load switching applications. The life rating of 40K cycles minimum
was calculated with 95% Weibull reliability.
Current vs Time
Electrical Data
(Over Temperature Range —
Max. Terminal Temp. = 200°C)
Make/Break Life for Capacitive &
Resistive Loads at 320 Vdc 1,2 —
@ 90% Capacitive Pre-Charge —
50,000 cycles
@ 70% Capacitive Pre-Charge —
50 cycles
@ -250 A (2 Consecutive, Reverse
Polarity) 1 — 10 cycles
@ 3300 A (Break only,
2 Consecutive) 1 — 4 cycles
Mechanical Life — 100,000 cycles
Notes:
1 Resistive load includes inductance
L = 25 µH. Load @ 2500 A tested
@ 200 µH.
2 Conductor: 2 each of copper
54 mm2 (AWG 0) required for
> 250 A carry. 1 Copper (AWG 0)
conductor recommended for
≤ 250 A
KILOVAC 28 – 1800 Vdc
Traditional Contactors
7
PAGE 59
KILOVAC 28 – 1800 Vdc Traditional Contactors
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
EV250-2A & 2B 400 Amps CZONKA II EVX Make & Break Load Switching
Product Facts
n Hydrogen dielectric for
power switching high
current loads
n 400 A carry, 2,500 A
interrupt @ 320 Vdc
n Suited for circuit protection,
control, battery switching,
and main power safety
disconnect
n Versatile power, voltage,
and current operating range:
28-1800 Vdc tested
n Internal coil economizer
provides:
n 4W typical hold power
independent of tempera-
ture & voltage range
n EMI spectrum tested and
approved
n Built-in coil suppression
n “Hammer effect”
mechanism breaks light
contact welds
n Hermetically
“Super-sealed”
environment chamber
uniquely protects ALL
moving parts
n Can operate in harsh
environments
n Moving contact rotates
to provide fresh contact
surface for low contact
resistance and low power
consumption
n Sealed control connector.
Mating connector with flying
leads Part Number 2005
available
n Special versions available:
n Economical (-8A/B) for
light duty power switch-
ing (without arc blowout
magnets)
n 10 inch flying leads
model (-7A)
Product Specifications
Contact Arrangement — SPST-NO
Contact Form — X
Continuous Current Carry, Max. —
400 A; 6.5 Minutes — 500 A
Break Current @ 320 Vdc —
2,500 A
Contact Resistance, Max. —
0.0003 ohm
Contact Resistance, Typ. —
0.0001 – 0.0002 ohm
Dielectric at Sea Level
(Leakage < 1mA) — 2,200 Vrms
Shock, 11ms, 1/2 Sine (Peak),
Operating — 30 g
Vibration, Sinusoidal
(80-2000 Hz, Peak) — 20 g
Operating Ambient Temperature
Range — -40°C to +85°C
Load Life — See chart on next page
Operate Time, @ 25°C —
Close (Includes Bounce), Typ. —
18 ms
Bounce (After Close Only), Max.
— 5 ms
Release Time (Includes Arcing),
Max. — 15 ms
Insulation Resistance @ 500 Vdc,
Min. — 100 mohm
Weight, Nominal —
1.76 lb (0.8 kg)
Coil Data**
EV250-2A EV250-2B
Voltage, Nominal* 12 Vdc 24 Vdc
Pickup (Close), Max. 9 Vdc 18 Vdc
Hold, Min. 7 Vdc 14 Vdc
Dropout (Open), Min. 5 Vdc 10 Vdc
Current (@ VsNom / 25°C)
Inrush 2.8 A 1.8 A
Holding, Standby 0.34 A 0.11 A
Inrush Time, Max. 200 ms 200 ms
* Other special coil voltages available upon request.
** Do not use a free wheeling diode or capacitor across the coil. Built in
suppression limits back EMF to zero volts.
Note: Dimensions in inches. Multiply values by 25.4 for dimensions in mm.
Contact Ratings*
* 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.
Ordering Information
Sample Part Number EV250 -2 A
Series:
Model:
2 = With Blowout Magnets
8 = Without Blowout Magnets
7 = 10” Flying Leads (12 V, with Magnets Only)
Coil Voltage:
A = 12 Vdc, Nominal
B = 24 Vdc, Nominal
For detailed specifications and recommendations, refer to the
EV250-2A & B or 7A sales drawings.
KILOVAC 28 – 1800 Vdc Traditional Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
EV250-2A & 2B 400 Amps CZONKA II EVX Make & Break Load Switching (Continued)
Life Ratings and Qualification Test Plan
Normal Operations Abnormal Operations
Test # 1 2 3 4
Current Reference Graph and -250 A 2500 A
Voltage Test Circuit Diagram (Sht. 8) 320 V 320 V
Load Type Capacitive Capacitive Resistive Resistive
% Pre Charge 90% 70% NA N/A
Switch Mode Make Only Make Only Make/Break Break Only
Sequence
1 10K cycles 10 cycles 2 2
2 10K 10 2 —
3 10K 10 2 —
4 10K 10 2 2
5 10K 10 2 —
Etc. Continue Cycling to Relay Failure
The testing objective is to verify proper relay function for a given number of consecutive and cumulative cycles under
both normal and abnormal conditions in a variety of load switching applications. The life rating of 40K cycles minimum
was calculated with 95% Weibull reliability.
Electrical Data
(Over Temperature Range —
Max. Terminal Temp. = 200°C)
Make/Break Life for Capacitive &
Resistive Loads at 320 Vdc 1,2 —
@ 90% Capacitive Pre-Charge —
50,000 cycles
@ 70% Capacitive Pre-Charge —
50 cycles
@ -250 A (2 Consecutive, Reverse
Polarity) 1 — 10 cycles
@ 3300 A (Break only,
2 Consecutive) 1 — 4 cycles
Mechanical Life — 100,000 cycles
Notes:
1 Resistive load includes inductance
L = 25 µH. Load @ 2500 A tested
@ 200 µH.
2 Conductor: 2 each of copper
54 mm2 (AWG 0) required for
> 250 A carry. 1 Copper (AWG 0)
conductor recommended for
≤ 250 A
KILOVAC 28 – 1800 Vdc
Traditional Contactors
7
PAGE 61
KILOVAC 28 – 1800 Vdc Traditional Contactors
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
EV500 “BUBBA” Contactor 600 Amps, Make & Break Load Switching
Product Facts
n Very high power sealed
contactor
n Hydrogen dielectric for
power switching high
current loads
n Excellent for safety
disconnect and transfer
switch applications
n Suited for circuit protection
control
n Hermetically “Super-sealed”
environment uniquely
protects contacts and all
moving parts; can operate
in harsh environments
n 600-1000 A continuous carry,
dependent on temperature
and conductors used
n 3,300 A interrupt, 1,000 A
make, @ 320 Vdc
n 12 and 24 volt coil control
options. Call TE for custom
options
n 360 kW power switch
capable
n 200°C hot power terminals
capable
n Bi-directional power
switching
n Auxiliary contacts optional
n Built-in dual power coil
economizer, 8W holding
typical
n Versatile power, voltage,
and current operating range:
28-1800 Vdc*
Product Specifications
Contact Arrangement with
Auxiliary Contacts —
Form X — SPST-NO
Form A — SPST-NO
Rated Resistive Load @ 270 Vdc,
85°C (Continuous/10 sec) —
600 A/1,600 A
Continuous Current Carry, Max.,
25°C 1 — 750 A
Overload Current @ 320 Vdc, Max. —
Make (Closed Into) — 1,000 A
Break (Open) — 3,300 A
Contact Resistance, Max. —
0.0002 ohm
Dielectric at Sea Level
(Leakage < 1mA) —
Open Power Terminal to Terminal —
2,000 Vrms
Closed Power Terminals to All Other
Points — 2,000 Vrms
Shock, 11ms, 1/2 Sine (Peak),
Operating — 30 g
Vibration, Sinusoidal (80-2000 Hz,
Peak) — EV500-5 — 5 g
EV500-4 — 10 g
Operating Ambient Temperature
Range — -40°C to +85°C
Load Life (Mechanical/
Electrical) 2 — See next page
Operate Time @ 25°C —
Close (Includes Bounce), Typ. —
40 ms
Bounce (After Close Only), Max.
— 5 ms
Release Time (Includes Arcing),
Max. at 2500 A — 20 ms
Insulation Resistance @ 500 Vdc,
Min. — 100 mohm
Weight, Nominal —
3.38 lb (1.53 kg)
Notes:
1. Current Carry: 750 A @ 25°C.
Derate 2.5 A/°C to 600 A @
85°C for still air, no heat sink.
Reference National Electric Code
for specific conductor size recom-
mendation versus current. For >
600 A carry, call TE and request
the “EV500 Current Carry study”
for additional data.
2. See EV500 sales drawing for
complete specifications, including
normal capacitive pre-charge
make, plus abnormal make and
break ratings.
Coil Data
12 V 24 V
Type Driver 2 Coil Electronic
Volts, Nominal* 12 Vdc 24 Vdc
Pickup (Close), Max. 9.9 Vdc 19.7 Vdc
Hold, Min. 9 Vdc 18 Vdc
Dropout (Open), Min. 2 Vdc 4 Vdc
Current (@ VsNom / 25°C)
Inrush 3.3 A 1.7 A
Holding, Standby 0.74 A 0.37 A
Inrush Time, Max. 300 ms 300 ms
Ordering Information
Sample Part Number EV500 4 A
Series:
Auxiliary Contacts:
4 = Without
5 = With
Coil Voltage:
A = 12 Vdc
B = 24 Vdc
Refer to EV500 Sales Drawing for complete specifications.
Electrical Life Cycles vs Power Switching
* Failure mode: Dielectric withstand voltage test @ 2000 Vdc, power terminal
to terminal, leakage exceeds 1.0 A.
KILOVAC 28 – 1800 Vdc Traditional Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
Life Ratings and Qualification Test Plan
Normal Operations Abnormal Operations
Test # 1 2 3 4
Current Reference Graph and -250 A 3300 A
Voltage Test Circuit Diagram (Sht. 8) 320 V 320 V
Load Type Capacitive Capacitive Resistive Resistive
% Pre Charge 90% 70% NA N/A
Switch Mode Make Only Make Only Make/Break Break Only
Sequence
1 10K cycles 10 cycles 2 2
2 10K 10 2 —
3 10K 10 2 —
4 10K 10 2 2
5 10K 10 2 —
Etc. Continue Cycling to Relay Failure
The testing objective is to verify proper relay function for a given number of consecutive and cumulative cycles under
both normal and abnormal conditions in a variety of load switching applications. The life rating of 40K cycles minimum
was calculated with 95% Weibull reliability.
Current vs Time
Electrical Data
(Over Temperature Range —
Max. Terminal Temp. = 200°C)
Make/Break Life for Capacitive &
Resistive Loads at 320 Vdc 1,2 —
@ 90% Capacitive Pre-Charge —
50,000 cycles
@ 70% Capacitive Pre-Charge —
50 cycles
@ -250 A (2 Consecutive, Reverse
Polarity) 1 — 10 cycles
@ 3300 A (Break only,
2 Consecutive) 1 — 4 cycles
Mechanical Life — 100,000 cycles
Notes:
1 Resistive load includes inductance
L = 25 µH.
2 Testing is limited at this time.
Consult TE for official ratings.
EV500 “BUBBA” Contactor 600 Amps, Make & Break Load Switching (Continued)
KILOVAC 28 – 1800 Vdc
Traditional Contactors
7
PAGE 63
KILOVAC 28 – 1800 Vdc Traditional Contactors
Product Facts
n 500 A carry, 1300 A make
overload, 3000 A break
overload, @ 320 Vdc
n Hydrogen dielectric for
power switching high
current loads
n Auxiliary contacts
n Coil power economizing —
8 W holding
n Versatile power, voltage,
and current operating range
n Excellent for safety
disconnect and transfer
switch applications
n Suited for circuit protection
and control
n Bi-directional power
switching
n Hermetically-sealed
contacts; can operate in
harsh environments
n Fast operate and release
time
n Low power consumption
Product Specifications
Contact Arrangement —
Form X — SPST-NO
Auxiliary Contact (28 Vdc, 0.1 A) —
SPST-NO
Rated Resistive Load @ 320 Vdc —
300 Amps @85˚C
Continuous Current Carry, Max. @
50°C — 500 A
Overload Current @ 320 Vdc —
Make — 1,300 A
Break — 3,300 A
Load Life, @ 320 Vdc, Min. —
See chart at right
Contact Resistance, Max. —
End of Life — 0.0002 ohm
Dielectric at Sea Level —
Power Terminals to Coil and All Other
Points — 1,800 Vrms
Shock, 11ms, 1/2 Sine (Peak) —
30 g
Vibration, Sinusoidal
(55-2000 Hz, Peak) — 5 g
Operating Ambient Temperature
Range — -40°C to +85°C
Operate Time, Including Bounce,
Max., 25°C — 40 ms
Release Time, Max. — 20 ms
Bounce Time, Max. — 5 ms
Insulation Resistance @ 500 Vdc,
Min. —
Initial — 100 mohm
End of Life — 50 mohm
Weight, Nominal —
3.4 lb (1.52 kg)
Coil Data
Volts, Nominal 12 V 24 V
Pickup, Max. @ 65°C 9.9 Vdc 19.7 Vdc
Hold, Max. @ 65°C 8.5 Vdc 17 Vdc
Dropout, Min. @ -35°C 1.2 Vdc 2.4 Vdc
Coil Power** 25°C
During Pickup (300 ms) 43 W 43 W
While Holding 8 W 8 W
Energy, Magnetic, Max.*** .26 J .26 J
** Two coils are employed for power economizing subsequent to pickup.
During pickup both coils operate in parallel drawing 43 Watts momentarily.
After pickup, the electronic economizing system leaves only the holding
coil on, drawing 8 Watts @ 25°C. Economizing system includes transient
voltage suppression.
*** Coil energy absorbed internally -4x nominal voltage.
Ordering Information
Sample Part Number PD350 X B 5 7
Series:
Contact Form:
X = SPST-NO, Double Make
Coil Voltage:
A = 12 Vdc, Stud Terminals
B = 24 Vdc, Stud Terminals
Power Terminals:
5 = Stud Terminals
Mounting:
7 = Panel Mount, Captive Bolts
Contact Rating Notes:
1. Maximum continuous current
carry = 500A @ 25°C = TA, derate
5A/°C for higher temp.
2. Maximum interrupt power
(break only) = 1 MW @ 200mH
inductance.
Electrical Life Cycles vs Power Switching
* Failure Mode: Dielectric withstand voltage test @ 2000 Vdc, power terminal
to terminal, leakage exceeds 1.0 mA. Current carry: 500 A @ 25°C. Derate
2.5 A/°C to 350 A @ 85°C for still air, no heat sink, AWG# 00 conductor.
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
PD350X - 500 Amps “BUBBA” Contactor, Make & Break Load Switching
KILOVAC High Voltage Relays and Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
KILOVAC
High Voltage Relays
7
PAGE 65
KILOVAC High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
Contact Isolation Carry Current Power RF Contact Form Part Number
Voltage Vdc Voltage Vdc (Amps DC) Switching Ratings Series
2000 5 Yes No SPST-NO AP5A
2000 5 Yes No SPST-NC AP5B
2000 5 Yes No SPDT AP5C
2000 10 Yes No SPST-NO AP10A
2000 10 Yes No SPST-NC AP10B
270 Vdc 2000 10 Yes No SPDT AP10P
Aerospace 2000 15 Yes No SPST-Latch AP44P
1800 5 Yes No SPST-NO PD5A
1800 5 Yes No SPST-NC PD5B
28 Vdc to 1800 Vdc 1800 10 Yes No SPST-NO PD10A
1800 10 Yes No SPST-NC PD10B
1800 10 Yes No SPST-Latch PD10P
2.0 kV 2000 6 Carry Only Yes SPST-NO S06CBA
2000 15 Yes Yes SPDT K45C
3.0 kV 3000 2 Carry Only No SPST-NO S02DNA
3500 8 Make Only No SPDT HC-5
3.5 kV 3500 15 Yes Yes SPDT HC-3*
3500 25 Carry Only Yes SPDT HC-1
5000 8 Carry Only No SPST-NO S06FNA218
5000 30 Yes Yes SPST-NO K41A
5000 30 Yes Yes SPST-NC K41B
5.0 kV 5000 30 Yes Yes SPDT K41C
5000 25 Yes Yes SPST-Latch K41P
5000 25 Yes Yes SPDT-Latch K41R
5000 35 Yes Yes SPST-Latch K40P
7.0 kV 7000 6 Carry Only Yes SPST-NO S06HBA
7.5 kV 7500 10 Make Only No DPDT KM-13
7500 10 Make Only No DPDT KM-17
8000 6 Carry Only No SPST-NC S06JNB
8000 8 Make Only No SPDT HC-6
8000 10 Yes Yes DPDT H-18
8.0 kV 8000 12 Yes Yes SPST-NO K47A
8000 12 Yes Yes SPST-NC K47B
8000 15 Yes No SPDT HC-4
8000 25 No No SPDT HC-2
8000 50 Yes Yes SPST-Latch K44P
*Consult factory for load switching level.
High Voltage Relays Quick Reference Guide
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
Contact Isolation Carry Current Power RF Contact Form Part Number
Voltage Vdc Voltage Vdc (Amps DC) Switching Ratings Series
10000 5 Yes No SPST-NO S05LTA
10000 5 Yes No SPST-NC S05LTB
10000 5-30 Special No SPST-NO K81A
10000 5-30 Special No SPST-NC K81B
10 kV 10000 5-30 Special No SPDT K81C
10000 25 Special Yes SPST-NO K43A
10000 25 Special Yes SPST-NC K43B
10000 25 Special Yes SPDT K43C
10000 24 Special Yes SPDT-Latch K43R
10000 24 Special Yes SPST-Latch K43P
12 kV 12000 30 Yes Yes DPDT H-14
12000 30 Yes Yes DPDT H-16
15000 5 Yes No SPST-NO S05MTA
15000 12 Make Only No SPDT KC-15
15000 12 Make Only No SPDT KC-16
15000 15 Yes Yes SPDT H-8
15000 15 Yes No SPDT KC-14
15 kV 15000 15 Yes No SPDT KC-18
15000 30 Yes No SPDT KC-12
15000 30 Carry Only Yes 4PDT H-26
15000 30 Yes No SPDT KC-8
15000 50 Carry Only Yes SPDT KC-2
15000 50 Carry Only Yes SPDT KC-11
20 kV 20000 30 Special Yes DPDT H-19
25000 15 Make Only No SPST-NC KC-38
25000 18 Special No SPST-NO K62A
25000 18 Special No SPST-NC K62B
25000 18 Special No SPDT K62C
25 kV 25000 30 Special Yes SPDT H-17
25000 30 Make Only No SPST-NO KC-28
25000 45 Special No SPST-NC KC-32
25000 55 Carry Only Yes SPST-NC KC-30
25000 65 Special No SPST-NO KC-22
25000 110 Carry Only Yes SPST-NO KC-20
30 kV 30000 30 Special Yes SPST-NC H-23
30000 30 Special Yes SPST-NO H-24
35000 10 Make Only No SPDT K60C
35 kV 35000 10 Make Only No SPST-NO K61A
35000 10 Make Only No SPST-NC K61B
35000 10 Make Only No SPDT K61C
50 kV 50000 10 Make Only No SPDT K64C
50000 30 Special No SPDT H-25
70000 10 Make Only No SPST-NO K70A
70 kV 70000 10 Make Only No SPST-NC K70B
70000 10 Make Only No SPDT K70C
*Consult factory for load switching level.
KILOVAC High Voltage Relays Quick Reference Guide (Continued)
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC 270+ Vdc
High Voltage Relays
7
PAGE 67
KILOVAC 270+ Vdc High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
Product Facts
n AP5 make and break 5 A;
AP10 make and break 10 A
@ 270 Vdc
n 20 A overload rating
n Latching actuator available
for low power consumption
n Ideal for applications from
28 to 1000 Vdc
n Small size and weight
n Wide variety of mounting
styles (see pages 54 and 55)
n No heat sinks required
n 2000 V isolation across
open contacts
n Vacuum-sealed contacts;
can operate in harsh
environments
n Qualified to SAE ARD 50031
n Space-rated version built in
accordance with customers
SCD
Product Specifications
Contact Arrangement —
AP5A — SPST-NO
AP5B — SPST-NC
AP5C — SPDT
Contact Form —
AP5A — A
AP5B — B
AP5C — C
Rated Resistive Load @ 270 Vdc
— 5 A*
Continuous Current Carry, Max. —
AP5A, AP5B, AP5C — 25 A**
Overload @ 270 Vdc —
AP5A, AP5B — 20 A
AP5C— 10 A
Contact Resistance, Max. —
10 mohm
Dielectric at Sea Level —
Coil to Case — 500 Vrms
All Other Points — 2,000 Vrms
Shock, 11ms, 1/2 Sine (Peak) —
AP5A, AP5B, AP5C— 50 g
Vibration, Sinusoidal
(55-2000 Hz, Peak) — 10 g
Operating Ambient Temperature
Range — -55°C to +85°C
Load Life @ 270 Vdc, Min. —
AP5A, AP5B — 50,000 cycles
AP5C — 10,000 cycles
Operate Time,
Excluding Bounce, Max. —
AP5A, AP5B, AP5C — 7 ms
Release Time, Max. —
AP5A, AP5B, AP5C — 10 ms
Bounce Time, Max. —
AP5A, AP5B, AP5C — 3 ms
Insulation Resistance @ 500 Vdc,
Min. —
Initial — 100 mohm
End of Life — 50 mohm
Weight, Nominal —
28 gram (1 oz.)
AP5A, AP5B, & AP5C Relays — 5 Amps
Product Specifications
Contact Arrangement —
AP10A — SPST-NO
AP10B — SPST-NC
AP10P — SPST Latching
Contact Form —
AP10A — A
AP10B — B
AP10P — P
Rated Resistive Load @ 270 Vdc
— 10 A*
Continuous Current Carry, Max. —
AP10A, AP10B — 25 A**
AP10P — 30 A**
Overload @ 270 Vdc — 20 A
Contact Resistance, Max. —
10 mohm
Dielectric at Sea Level —
Coil to Case — 500 Vrms
All Other Points — 2,000 Vrms
Shock, 11ms, 1/2 Sine (Peak) —
50 g
Vibration, Sinusoidal
(55-2000 Hz, Peak) — 10 g
Operating Ambient Temperature
Range — -55°C to +85°C
Load Life @ 270 Vdc, Min. —
AP10A — 10,000 cycles
AP10B, AP10P — 7,000 cycles
Operate Time,
Excluding Bounce, Max. —
AP10A, AP10B — 7 ms
AP10P — 4 ms
Release Time, Max. —
AP10A, AP10B — 10 ms
AP10P — N/A
Bounce Time, Max. —
AP10A, AP10B — 3 ms
AP10P — 2 ms
Insulation Resistance @ 500 Vdc,
Min. —
Initial — 100 mohm
End of Life — 50 mohm
Weight, Nominal —
28 gram (1 oz.)
AP10A, AP10B, AP10P & AP11A Relays — 10 Amps
Notes:
* The load terminals should always
be connected as follows: Common
Contact +; Other Contact –.
** 10 amps for PC board connection.
Coil Data
Volts, Nominal 12 28 28 2 120
Pickup, Max. 1 10 Vdc 20 Vdc 16 Vdc 85 Vdc
Dropout, Min. .3-6 Vdc .7-12 Vdc N/A 5-55 Vdc
Coil Resistance (±10%) 53 Ω 290 Ω 80 Ω 4700 Ω
Coil resistance rated at 25°C
Notes:
1. Value for AP5C is 24 for 28 Vdc coil & 100 for 120 Vdc coil
2. Latching
Ordering Information
Sample Part Number AP5 C 3 4 5
Series:
Contact Form:
A = SPST-NO B = SPST-NC C = SPDT
P = SPST Latching
Coil Voltage:
2 = 12Vdc, Bus Wire/PC Board
3 = 28 Vdc, Bus Wire/PC Board
5 = 120 Vdc, Bus Wire/PC Board
7 = 12 Vdc, Turret Terminals
8 = 28 Vdc, Turret Terminals
9 = 120 Vdc, Turret Terminals
A = 12 Vdc, Stud Terminals, Panel Mount
B = 28 Vdc, Stud Terminals, Panel Mount
C = 120 Vdc, Stud Terminals, Panel Mount
Power Terminals:
3 = Solder Connection/PC Board 4 = Flying Leads
5 = Stud Terminals, Panel Mount
Mounting:
2 = Flanged Mount 4 = Through Chassis Mount
5 = PCB Mount 7 = Panel Mount
AP5/AP10 Relays
KILOVAC 270+ Vdc High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
AP5/AP10 Relays (Continued)
Through chassis style
mounting with solder type
power terminals and turret coil
terminals (Available in forms
A, B, & C)
AP5A834 Shown as
Part Number Sample
Through chassis style
mounting with solder type
power terminals and bus wire
coil leads (Available in forms
A, B, C, P)
AP10A334 Shown as
Part Number Sample
Flanged style mounting with
solder type power terminals
and turret coil terminals
(Available in forms A, B, & C)
AP5C832 Shown as
Part Number Sample
Flanged style mounting with
solder type power termi-
nals and bus wire coil leads
(Available in forms A, B, C,
P)
AP5C332 Shown as
Part Number Sample
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC 270+ Vdc
High Voltage Relays
7
PAGE 69
KILOVAC 270+ Vdc High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
PC board style mounting with
PC board terminals (Available
in forms A, B, & C)
AP10A335 Shown as
Part Number Sample
Panel style mounting with flying
power leads and stud terminals
(Available in forms A & B)
AP10AB47 Shown as
Part Number Sample
Panel style mounting with
stud terminals (Available in
forms A & B)
AP10AB57 Shown as
Part Number Sample
AP5/AP10 Relays (Continued)
KILOVAC 270+ Vdc High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
Product Facts
n 15 A make and break @
270 Vdc
n 45 A carry
n 60 A overload rating
n Ideal for high voltage
applications from 28 to
270 Vdc
n Latching actuator for low
power consumption
n 2000 V isolation across
open contacts
n Small size and weight
n Space-rated version built in
accordance with customers
SCD
n Meets many requirements
of MIL-PRF-32085 Product Specifications
Contact Arrangement —
SPST Latching
Contact Form — P
Rated Resistive Load @ 270 Vdc
— 15 A*
Continuous Current Carry, Max.
— 45 A
Overload @ 270 Vdc — 60 A
Contact Resistance, Max. —
10 mohm
Dielectric at Sea Level —
Coil to Case — 500 Vrms
All Other Points — 2,000 Vrms
Shock, 11ms, 1/2 Sine (Peak) —
50 g
Vibration, Sinusoidal
(55-2000 Hz, Peak) — 15 g**
Operating Ambient Temperature
Range — -55°C to +85°C
Load Life @ 270 Vdc, Min. —
5,000 cycles
Operate Time,
Excluding Bounce, Max. — 2 ms
Release Time, Max. — N/A
Bounce Time, Max. — 3 ms
Latch/Reset Time, Including
Bounce, Max. — 5 ms
Insulation Resistance @ 500 Vdc,
Min. —
Initial — 100 mohm
End of Life — 50 mohm
Weight, Nominal —
43 gram (1.5 oz.)
Notes:
* The load terminals should always
be connected as follows: Common
Contact +; Other Contact –.
Coil Data
AP44P 28 Latching
Latch, Max. 22 Vdc
Reset, Max. 22 Vdc
Coil Resistance (±10%) 80 Ω
Coil resistance rated at 25°C
Ordering Information
Sample Part Number PD5 A 2 3 5
Series:
Contact Form:
P = SPST Latching
Coil Voltage:
3 = 28 Vdc, Bus Wire
Power Terminals:
3 = Solder Connection
Mounting:
4 = Standard
AP44P — 15 Amps
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC 280 – 1800 Vdc
High Voltage Relays
7
PAGE 71
KILOVAC 280 – 1800 Vdc High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
Product Facts
n Vacuum dielectric for power
switching
n Excellent for control
applications
n PCB and panel mountings
n Rugged design for the most
demanding applications,
including seismic shock
n Small size and weight
n Low power consumption
n No heat sinks required
n Vacuum-sealed; can operate
in explosive and harsh
environments
n 2000 V isolation across
open contacts
Product Specifications
Contact Arrangement —
PD5A — SPST-NO
PD5B — SPST-NC
Contact Form —
PD5A — A**
PD5B — B**
Rated Resistive Load @ 320 Vdc
— 5 A
Continuous Current Carry, Max.
@ 85°C — 15 A
Overload @ 320 Vdc, (Make/
Break) — 20 A
Life, (Mechanical/Rated Load) —
500k cycles/50k cycles
Contact Resistance, Max.,
End of Life — 0.010 ohm
Dielectric at Sea Level —
Power Terminals to Coil and
All Other Points — 1,800 Vrms
Shock, 11ms, 1/2 Sine (Peak) —
25 g
Vibration, Sinusoidal
(55-2000 Hz, Peak) — 5 g
Operating Ambient Temperature
Range — -40°C to +85°C
Operate Time, Max., Including
Bounce @ 25°C — 10 ms
Release Time, Max., Including
Bounce @ 25°C — 10 ms
Insulation Resistance @ 500 Vdc,
Min. —
Initial/End of Life — 100 mohm/50 mohm
Weight, Nominal —
57 g (.125 lb)
Note:
** Contact TE for availability of other
contact forms
Ordering Information
Sample Part Number PD5 A 2 3 5
Series:
Contact Form:
A = SPST-NO
B = SPST-NC
C = SPDT (PCB Only)
Coil Voltage:
2 = 12 Vdc, PCB Version 3 = 24 Vdc, PCB Version
5 = 125 Vdc, PCB Version
A = 12 Vdc, Panel Mount Version
B = 24 Vdc, Panel Mount Version
C = 125 Vdc, Panel Mount Version
Power Terminals:
3 = PCB Solder Connection
5 = Stud Terminal, Panel Mount
Mounting:
5 = PCB Mount 7 = Panel Mount
Coil Data
Nominal Volts DC 12 Vdc 24 Vdc 125 Vdc
Max. Coil Voltage 14 Vdc 28 Vdc 130 Vdc
Pickup, Max. @ 85°C 8 Vdc 16 Vdc 80 Vdc
Hold, Min. @ 85°C 3.3 Vdc 10 Vdc 33 Vdc
Dropout, Min. @ -40°C .5 Vdc 1 Vdc 5 Vdc
Coil Resistance (±10%) 70 Ω 290 Ω 4700 Ω
Ratings listed are for 25°C, sea level conditions
Contact Ratings*
* Based on extrapolated data. Since each application is unique, user is encour-
aged to verify rating in actual application. The load terminals should always be
connected as follows: Common Contact (A2) positive; Other Contact negative.
PD5 Make & Break Load Switching
KILOVAC 280 – 1800 Vdc High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
Product Facts
n Excellent for control
applications
n PCB and panel mountings
n Rugged design for the most
demanding applications,
including seismic shock
n Small size and weight
n Low power consumption
n No heat sinks required
n Vacuum-sealed; can operate
in explosive and harsh
environments
n 2000 V isolation across
open contacts
n Vacuum dielectric for power
switching
Product Specifications
Contact Arrangement —
PD10A — SPST-NO
PD10B — SPST-NC
PD10P*** — SPST-Latching
Contact Form —
PD10A — A**
PD10B — B**
PD10P*** — P**
Rated Resistive Load @ 320 Vdc
— 10 A
Continuous Current Carry, Max.
@ 85°C —
PD10A and PD10B — 25 A
PD10P*** — 30 A
Overload @ 320 Vdc, (Make/
Break) — 20 A
Life, (Mechanical/Rated Load) —
PD10A and PD10B —
500k cycles/10k cycles
PD10P*** — 7,000 cycles
Contact Resistance, Max.,
End of Life —
PD10A and PD10B — 0.010 ohm
PD10P*** — 0.030 ohm
Dielectric at Sea Level —
Power Terminals to Coil and
All Other Points —
PD10A and PD10B — 1,800 Vrms
PD10P*** — 2,000 Vrms
Shock, 11ms, 1/2 Sine (Peak) —
25 g
Vibration, Sinusoidal
(55-2000 Hz, Peak) — 5 g
Operating Ambient Temperature
Range —
PD10A and PD10B — -40°C to +85°C
PD10P*** — -35°C to +65°C
Operate Time, Max., Including
Bounce @ 25°C —
PD10A and PD10B — 10 ms
PD10P*** — 6 ms
Release Time, Max., Including
Bounce @ 25°C —
PD10A and PD10B — 10 ms
PD10P*** — 6 ms
Insulation Resistance @ 500 Vdc,
Min. —
Initial/End of Life — 100 mohm/50 mohm
Weight, Nominal —
71 g (.156 lb)
Notes:
** Contact TE for availability of other
contact forms
*** Not available in package shown,
package is the same as the
K41P.
Ordering Information
Sample Part Number PD10 A A 5 7
Series:
Contact Form:
A = SPST-NO
B = SPST-NC
P = SPST-Latching
Coil Voltage:
2 = 12 Vdc, PCB Version 3 = 24 Vdc, PCB Version
5 = 125 Vdc, PCB Version
A = 12 Vdc, Panel Mount Version
B = 24 Vdc, Panel Mount Version
C = 125 Vdc, Panel Mount Version
Power Terminals:
3 = PCB Solder Connection
5 = Stud Terminal, Panel Mount
Mounting:
5 = PCB Mount 7 = Panel Mount
Coil Data
Nominal Volts DC 12 Vdc 24 Vdc 125 Vdc
Max. Coil Voltage 14 Vdc 28 Vdc 130 Vdc
Pickup, Max. @ 85°C 8 Vdc 16 Vdc 80 Vdc
Hold, Min. @ 85°C 3.3 Vdc 10 Vdc 33 Vdc
Dropout, Min. @ -40°C .5 Vdc 1 Vdc 5 Vdc
Coil Resistance (±10%) 70 Ω 290 Ω 4700 Ω
Ratings listed are for 25°C, sea level conditions
Contact Ratings*
* Based on extrapolated data. Since each application is unique, user is encour-
aged to verify rating in actual application. The load terminals should always be
connected as follows: Common Contact (A2) positive; Other Contact negative.
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.
PD10 Make & Break Load Switching
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC
High Voltage Relays
7
PAGE 73
KILOVAC High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
K45C
Product Facts
n Small, low profile 2 kV relay
n Vacuum dielectric for power
switching low current loads
n Single pole, double throw
contacts
n Widely used in H.F.
communication equipment
n Meets requirements of
MIL-R-83725
n Low power consumption
Product Specifications
Contact Arrangement —
SPDT
Contact Form — C
Test Voltage, DC or 60 Hz (Peak) —
4 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 2 kV
2.5 MHz — 1.8 kV
16 MHz — 1.4 kV
32 MHz — 1.1 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 20 A
2.5 MHz — 16 A
16 MHz — 10 A
32 MHz — 6 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts — 1.6 pF
Open Contacts to Ground — 2 pF
Contact Resistance, Max. —
0.05 ohm
Operate Time, Max. — 10 ms
Release Time, Max. — 10 ms
Shock, 11ms, 1/2 Sine (Peak) —
30 g
Vibration —
Peak — 10 g (10 to 2000 Hz)
Operating Ambient Temperature
Range — -55°C to +125°C
Mechanical Life
2 million cycles
Weight, Nominal —
21.26 g (0.75 oz.)
Ordering Information
Sample Part Number K45 C 3 3 4
Series:
Contact Form:
C = SPDT
Coil Voltage:
2 = 12 Vdc, Bus Wire
3 = 26.5 Vdc, Bus Wire
High Voltage Connections:
3 = Solder Connection
Mounting:
2 = Flanged
4 = Standard
See page 7-87 for mounting methods.
Coil Data
Volts, Nominal DC 12 V 26.5 V
Pickup, Max. 8 Vdc 16 Vdc
Hold, Max. @ 65°C 8.5 Vdc 17 Vdc
Dropout .5-5 Vdc 1-10 Vdc
Coil Resistance (±10%) 230 Ω 920 Ω
Ratings listed are for 25°C, sea level conditions.
K45 Series Make & Break Load Switching — 1.5 - 2 kV Relays
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
HC-1
No Load Switching
HC-3
Make & Break Load
Switching
Product Facts for HC-1
n Widely used for RF
applications
n Vacuum dielectric for low
leakage current applications
n Copper contacts for high
current capability
n Not designed for power
switching
n Meets requirements of
MIL-R-83725
n QPL version available,
M83725/5-001
HC-5
Make Only Load Switching
Product Facts for HC-5
n Gas-filled for “make only”
power switching
n SF-6 gas-filled for
capacitive discharge
applications
n Tungsten contacts for
long life when power
switching
Product Specifications for
HC-1, HC-3 and HC-5
Contact Arrangement — SPDT
Contact Form — C
Test Voltage, DC or 60 Hz (Peak) —
5 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 3.5 kV
2.5 MHz — 2.5 kV
16 MHz — 2 kV
32 MHz — 1.5 kV
Continuous Carry Current, Max. —
DC or 60 Hz — HC-1 — 25 A
HC-3 — 18 A
HC-5 — 8 A
2.5 MHz — HC-1 — 14 A
16 MHz — HC-1 — 9 A
32 MHz — HC-1 — 7 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts —
HC-1 —2 pF
Open Contacts to Ground —
HC-1 —2.5 pF
Contact Resistance, Max. —
HC-1 — 0.01 ohm
HC-3 — 0.02 ohm
HC-5 — 0.50 ohm*
Operate Time, Max. — 6 ms
Release Time, Max. — 6 ms
Shock, 11ms, 1/2 Sine (Peak) —
50 g
Vibration —
Peak — 10 g (55 to 2000 Hz)
Operating Ambient Temperature
Range — -55°C to +125°C
Mechanical Life —
HC-1, HC-3 — 2 million cycles
HC-5 — 1 million cycles
Weight, Nominal —
28.35 g (1.0 oz.)
Note:
* Contact resistance for gas-filled
relays is measured at 28 Vdc, 1
Amp
Ordering Information
Sample Part Number HC- 1 /12Vdc
Series:
Model:
1
3
5
Coil Voltage:
Blank = 26.5 Vdc
/12Vdc = 12 Vdc
/115Vdc = 115 Vdc
Coil Data
Pickup, Max. 8 Vdc 16 Vdc 80 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-50 Vdc
Coil Resistance (±10%) 80 Ω 335 Ω 6000 Ω
Ratings listed are for 25°C, sea level conditions
Product Facts for HC-3
n Tungsten contacts for
long life when power
switching
n Vacuum dielectric for power
switching low current loads
HC Series — 3.5 kV Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC
High Voltage Relays
7
PAGE 75
KILOVAC High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
K41A, K41B
Product Facts
n High current carry rating
n Vacuum dielectric for power
switching low current loads
n Glazed ceramics for low
current leakage
n Compact, space-saving
design
n Meets requirements of
MIL-R-83725
n QPL versions available,
M83725/21 & M83725/22
K41C
Product Facts
n Single pole, double throw
version
n Vacuum dielectric for power
switching low current loads
n RF ratings to 32 MHz
n Long life: 2 million cycles
n Meets requirements of
MIL-R-83725
n QPL version available,
M83725/23
Product Specifications for
K41A, K41B and K41C
Contact Arrangement —
K41A — SPST-NO
K41B — SPST-NC
K41C — SPDT
Contact Form —
K41A — A
K41B — B
K41C — C
Test Voltage, DC or 60 Hz (Peak) —
6 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 5 kV
2.5 MHz — 4.5 kV
16 MHz — 3.5 kV
32 MHz — 2.8 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 30 A
2.5 MHz — 24 A
16 MHz — 16 A
32 MHz — 12 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts — 1.2 pF
Open Contacts to Ground — 1.2 pF
Contact Resistance, Max. —
0.02 ohm
Operate Time, Max. — 10 ms
Release Time, Max. — 10 ms
Shock, 11ms, 1/2 Sine (Peak) —
50 g
Vibration —
Peak — 10 g (55 to 2000 Hz)
Operating Ambient Temperature
Range — -55°C to +125°C
Mechanical Life — 2 million cycles
Weight, Nominal —
28.35 g (1.0 oz.)
Coil Data
Nominal Volts DC 12 Vdc 26.5 Vdc 115 Vdc
Pickup, Max. 8 Vdc 16 Vdc 80 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-50 Vdc
Coil Resistance (±10%) 70 Ω 290 Ω 4700 Ω
Ratings listed are for 25°C, sea level conditions
Ordering Information
Sample Part Number K41 A 3 3 4
Series:
Contact Form:
A = SPST-NO B = SPST-NC C = SPDT
Coil Voltage:
2 = 12 Vdc, Bus Wire 3 = 26.5 Vdc, Bus Wire
5 = 115 Vdc, Bus Wire 7 = 12 Vdc, Turret Terminal*
8 = 26.5 Vdc, Turret Terminal*
9 = 115 Vdc, Turret Terminal*
High Voltage Connections:
3 = Solder Connection
Mounting:
2 = Flanged 4 = Standard
* See page 7-87 for turret
terminal dimensions and
mounting methods.
K41 Series Make & Break Load Switching — 5.0 kV Relays
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
K41P
Product Facts
n Fast, 6 millisecond operate
time
n Vacuum dielectric for power
switching low current loads
n Latching actuator for low
power consumption
n Ideal for frequency agile
communication systems
n Meets requirements of
MIL-R-83725
n QPL version available,
M83725/24
K41R
Product Facts
n Latching actuator for low
power consumption
n Vacuum dielectric for power
switching low current loads
n Meets requirements of
MIL-R-83725
n Latching version of K41C
Product Specifications for
K41P and K41R
Contact Arrangement —
K41P — SPST-Latching
K41R — SPDT-Latching
Contact Form —
K41P — P
K41R — R
Test Voltage, DC or 60 Hz (Peak) —
6 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 5 kV
2.5 MHz — K41P — 4.5 kV
K41R — 4.0 kV
16 MHz — K41P — 3.5 kV
K41R — 3.2 kV
32 MHz — K41P — 2.8 kV
K41R — 2.5 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 30 A
2.5 MHz — K41P — 20 A
K41R — 16 A
16 MHz — K41P — 13 A
K41R — 10 A
32 MHz — K41P — 10 A
K41R — 6 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts —
K41P — 1.2 pF
K41R — 1.6 pF
Open Contacts to Ground —
K41P — 1.2 pF
K41R — 1.6 pF
Contact Resistance, Max. —
0.02 ohm
Operate Time, Max. — 6 ms
Release Time, Max. — N/A
Shock, 11ms, 1/2 Sine (Peak) —
K41P — 50 g
K41R — 30 g
Vibration —
Peak — 10 g (55 to 2000 Hz)
Operating Ambient Temperature
Range — -55°C to +125°C
Insulation Resistance —
Initial — 10 gigaohms
Mechanical Life — 1 million cycles
Weight, Nominal —
28.35 g (1.0 oz.)
Coil Data
Volts, Nominal 26.5 Vdc
Reset & Latch, Max. 16 Vdc
Dropout N/A
Coil Resistance (±10%) 80 Ω
Ratings listed are for 25°C, sea level
conditions.
K41 Series Make & Break Load Switching — 5.0 kV Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
Ordering Information
Sample Part Number K41 P 3 3 4
Series:
Contact Form:
P = SPST-Latching R = SPDT-Latching
Coil Voltage:
3 = 26.5 Vdc, Bus Wire
High Voltage Connections:
3 = Solder Connection
Mounting:*
2 = Flanged 4 = Standard
* See page 7-87 for mounting methods.
KILOVAC
High Voltage Relays
7
PAGE 77
KILOVAC High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
Product Facts for K40P
n Vacuum dielectric for power
switching low current loads
n Fast, 1 millisecond operate
time
n Long life: 10 million cycles
n 35 Amps continuous current
rating at DC; 8 Amps at 32
MHz
n Ideal for high power
antenna couplers
n Meets requirements of
MIL-R-83725
Product Facts for K40P364
n Double sided terminals for
ease of connection to bus
bar
n Vacuum dielectric for power
switching low current loads
n Fast switching, high current
capabilities
n Small and lightweight
Product Specifications
Contact Arrangement —
SPST-Latching
Contact Form — P
Test Voltage, DC or 60 Hz (Peak) —
6 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 5 kV
2.5 MHz — 4.5 kV
16 MHz — 3.5 kV
32 MHz — 2.8 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 35 A
2.5 MHz — 21 A
16 MHz — 14 A
32 MHz — 8 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts — 1.2 pF
Open Contacts to Ground — 1.2 pF
Contact Resistance, Max. —
0.02 ohm
Operate Time, Max. — 1 ms
Release Time, Max. — N/A
Shock, 11ms, 1/2 Sine (Peak) —
50 g
Vibration —
Peak — 30 g (55 to 2000 Hz)
Operating Ambient Temperature
Range — -55°C to +125°C
Mechanical Life —10 million cycles
Weight, Nominal —
28.35 g (1.0 oz.)
Coil Data
Volts, Nominal 26.5 Vdc
Reset & Latch, Max. 16 Vdc
Dropout N/A
Coil Resistance (±10%) 80 Ω
Ratings listed are for 25°C, sea level
conditions.
K40P Make & Break Load Switching — 5.0 kV Relays
Ordering Information
Sample Part Number K40 P 3 3 2
Series:
Contact Form:
P = SPST-Latching
Coil Voltage:
3 = 26.5 Vdc, Bus Wire
High Voltage Connections:
3 = Solder Connection
6 = Double Sided Solder Connection
Mounting:*
2 = Flanged 4 = Standard
* See page 7-87 for mounting methods.
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
Ordering Information
Sample Part Number KM- 17 /26Vdc
Series:
Model:
17
Coil Voltage:
Blank = 12 Vdc
/26.5Vdc = 26.5 Vdc
KM-17 Series Make Only Load Switching — 7.5 kV Relays
Product Specifications for
KM-17
Contact Arrangement — DPDT
Contact Form — 2C
Test Voltage, DC or 60 Hz (Peak) —
14 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 7.5 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 10 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts — N/A
Open Contacts to Ground — N/A
Contact Resistance, Max. —
0.5 ohm*
Operate Time, Max. — 20 ms
Release Time, Max. — 20 ms
Shock, 11ms, 1/2 Sine (Peak) —
10 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Ambient Temperature
Range — -20°C to +65°C
Insulation Resistance —
Initial — 10 gigaohms
Mechanical Life
— 10l0,000 cycle
Weight, Nominal —
KM-17 — 311.8 g (11 oz.)
Product Facts
n Double pole, double throw
contacts
n SF-6 gas-filled for ideal
discharge waveform
n High voltage flying leads
n Tabs for easy mount
n Widely used in defibrillator
applications
Coil Data
Nominal Volts DC 12 Vdc 26 Vdc
Pickup, Max. 8 Vdc 16 Vdc
Dropout .5-5 Vdc 1-10 Vdc
Coil Resistance (±10%) 12 Ω 48 Ω
Ratings listed are for 25°C, sea level conditions
Coils are not for continuous duty.
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KILOVAC
High Voltage Relays
7
PAGE 79
KILOVAC High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
K47 Series Make & Break Load Switching — 8 kV Relays
K47A
Product Facts for K47A
n Widely used in antenna
coupler applications
n Short actuator, low profile,
8 kV relay
n Vacuum dielectric for power
switching low current loads
n Normally open contacts
n Meets requirements of
MIL-R-83725
K47B
Product Facts for K47B
n Normally closed version of
K47
n Vacuum dielectric for power
switching low current loads
n 707 Ohm coil for low power
consumption
n Meets requirements of
MIL-R-83725
n QPL version available,
M83725/18-003
Product Specifications for
K47A and K47B
Contact Arrangement —
K47A — SPST-NO
K47B — SPST-NC
Contact Form —
K47A — A
K47B — B
Test Voltage, DC or 60 Hz (Peak) —
9 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 8 kV
2.5 MHz — 7.5 kV
16 MHz — 7 kV
32 MHz — 5 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 12 A
2.5 MHz — 10 A
16 MHz — 5 A
32 MHz — 3 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts — 1.2 pF
Open Contacts to Ground — 1.2 pF
Contact Resistance, Max. —
0.03 ohm
Operate Time, Max. — 10 ms
Release Time, Max. — 10 ms
Shock, 11ms, 1/2 Sine (Peak) —
30 g
Vibration —
Peak — 10 g (55 to 1000 Hz)
Operating Ambient Temperature
Range — -55°C to +125°C
Mechanical Life — 2 million cycles
Weight, Nominal —
25.5 g (0.9 oz.)
Coil Data
Nominal Volts DC 12 Vdc 26.5 Vdc
Pickup, Max. 8 Vdc 16 Vdc
Dropout .5-5 Vdc 1-10 Vdc
Coil Resistance (±10%) 230 Ω 707 Ω
Ratings listed are for 25°C, sea level conditions
Ordering Information
Sample Part Number K47 A 3 3 4
Series:
Contact Form:
A = SPST-NO B = SPST-NC
Coil Voltage:
2 = 12 Vdc, Bus Wire
3 = 26.5 Vdc, Bus Wire
High Voltage Connections:
3 = Solder Connection
Mounting:
2 = Flanged 4 = Standard
* See page 7-87 for mounting
methods.
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
HC Series — 8 kV Relays
HC-2
No Load Switching
HC-4
Make & Break Load
Switching
Product Facts for HC-2
n Vacuum dielectric and
copper contacts for high
current carry rating of 25
Amps
n Not designed for power
switching
n Stable, low contact
resistance
n Meets requirements of
MIL-R-83725
Product Facts for HC-4
n Tungsten contacts for long
life in power switching
applications
n Vacuum dielectric for arc
suppression when making
or breaking a load
n Meets requirements of
MIL-R-83725
Product Specifications for
HC-2, HC-4 and HC-6
Contact Arrangement — SPDT
Contact Form — C
Test Voltage, DC or 60 Hz (Peak) —
10 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 8 kV
Continuous Carry Current, Max. —
DC or 60 Hz — HC-2 — 25 A RMS
HC-4 — 15 A RMS
HC-6 — 8 A RMS
Coil Hi-Pot (Vrms, 60 Hz) — 500 A RMS
Contact Capacitance —
Between Open Contacts — N/A
Open Contacts to Ground — N/A
Contact Resistance, Max. —
HC-2 — 0.01 ohm
HC-4 — 0.02 ohm
HC-6 — 0.5 ohm*
Operate Time, Max. — 6 ms
Release Time, Max. — 6 ms
Shock, 11ms, 1/2 Sine (Peak) —
50 g
Vibration —
Peak — 10 g (55 to 2000 Hz)
Operating Ambient Temperature
Range — -55°C to +125°C
Mechanical Life —
HC-2 and HC-4 — 2 million cycles
HC-6 — 1 million cycle
Weight, Nominal —
39.69 g (1.4 oz.)
* Contact resistance for gas-filled
relays is measured at 28 Vdc, 1 Amp
HC-6
Make Only Load Switching
Product Facts for HC-6
n Tungsten contacts for
switching high in-rush loads
n SF-6 gas-filled for
capacitive discharge
applications
n Suitable for ESD testing
applications
n Tungsten contacts for long
life in power switching
applications
Ordering Information
Sample Part Number HC- 6 /12Vdc
Series:
Model:
2 4 6
Coil Voltage:
Blank = 26.5 Vdc
/12Vdc = 12 Vdc
/115Vdc = 115 Vdc
Coil Data
Nominal Volts DC 12 Vdc 26.5 Vdc 115 Vdc
Pickup, Max. 8 Vdc 16 Vdc 80 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-50 Vdc
Coil Resistance (±10%) 80 Ω 335 Ω 6000 Ω
Ratings listed are for 25°C, sea level conditions
KILOVAC
High Voltage Relays
7
PAGE 81
KILOVAC High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
H-18 Series Make & Break Load Switching — 8 kV Relays
Ordering Information
Sample Part Number H-18 /12Vdc
Series:
Model:
H-18
Coil Voltage:
Blank = 26.5 Vdc
/12Vdc = 12 Vdc
/115Vdc = 115 Vdc
Product Facts
n Smallest DPDT high voltage
relay
n Vacuum dielectric for power
switching low current loads
n 8 kV rating; carries 2 Amps
at 32 MHz
n Tungsten contacts for power
switching low current loads
n Meets requirements of
MIL-R-83725
Product Specifications
Contact Arrangement —
DPDT
Contact Form — 2C
Test Voltage, DC or 60 Hz (Peak) —
10 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 8 kV
2.5 MHz — 5 kV
16 MHz — 3 kV
32 MHz — 2 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 10 A
2.5 MHz — 7 A
16 MHz — 3 A
32 MHz — 2 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts — 0.8 pF
Open Contacts to Ground — 1.5 pF
Contact Resistance, Max. —
0.02 ohm
Operate Time, Max. — 15 ms
Release Time, Max. — 15 ms
Shock, 11ms, 1/2 Sine (Peak) —
30 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Ambient Temperature
Range — -55°C to +125°C
Mechanical Life — 1 million cycles
Weight, Nominal —
70.87 g (2.5 oz.)
Coil Data
Volts, Nominal DC 12 V 26.5 V 115 V
Pickup, Max. 8 Vdc 16 Vdc 80 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-50 Vdc
Coil Resistance (±10%) 60 Ω 250 Ω 3500 Ω
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
K44P Make & Break Load Switching — 9 kV Relays
Product Specifications
Contact Arrangement —
SPST-Latching
Contact Form — P
Test Voltage, DC or 60 Hz (Peak) —
9kVdc
Rated Operating Voltage (Peak) —
DC or 60 Hz — 8 kV
2.5 MHz — 7 kV
16 MHz — 6 kV
32 MHz — 4 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 50 A
2.5 MHz — 40 A
16 MHz — 25 A
32 MHz — 20 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts — 2.5 pF
Open Contacts to Ground — 2.8 pF
Contact Resistance, Max. —
0.01 ohm
Operate Time, Max. — 5 ms
Release Time, Max. — N/A
Shock, 11ms, 1/2 Sine (Peak) —
50 g
Vibration —
Peak — 20 g (55 to 2000 Hz)
Operating Ambient Temperature
Range — -55°C to +85°C
Mechanical Life — 1 million cycles
Weight, Nominal —
59.53 g (2.1 oz.)
Coil Data
Volts, Nominal 26.5 Vdc
Latch & Reset, Max. 23 Vdc
Dropout N/A
Coil Resistance (±10%) 155 Ω
Ratings listed are for 25°C, sea level
conditions
Product Facts
n Single pole, single throw
contacts with latching
actuator
n Vacuum dielectric for power
switching low current loads
n 20 G vibration rating
n Carries 50 Amps at DC
n Space rated versions
available
n Meets requirements of
MIL-R-83725
Ordering Information
Sample Part Number K44 P 3 3 4
Series:
Contact Form:
P = SPST-Latching
Coil Voltage:
3 = 26.5 Vdc, Bus Wire
High Voltage Connections:
3 = Solder Connection
Mounting:
2 = Flanged 4 = Standard
* See page 7-87 for mounting methods.
KILOVAC
High Voltage Relays
7
PAGE 83
KILOVAC High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
K81 A/B Series Make & Break Load Switching — 10 kV Relays
Ordering Information
Sample Part Number K81 A 3 3 5
Series:
Contact Form:
A = SPST-NO B = SPST-NC
Coil Voltage:
2 = 12 Vdc, PC Board 3 = 26.5 Vdc, PC Board
5 = 115 Vdc, PC Board
A = 12 Vdc, Stud Terminals, Panel Mount
B = 26.5 Vdc, Stud Terminals, Panel Mount
C = 115 Vdc, Stud Terminals, Panel Mount
High Voltage Connections:
A* = PCB Solder Connection — 20 Amp
3 = PCB Solder Connection — 5 Amp
4 = Flying Leads 5 = Stud Terminals
Mounting:
5 = PC Board 7 = Panel Mount
Product Facts
n 10 kV PC board-mount relay
n Vacuum dielectric for power
switching low current loads
n Flying leads or PCB mount
for high voltage connections
n Meets requirements of
MIL-R-83725
n Completely sealed; suitable
for test equipment
n Panel mount available for
ease of mounting
Product Specifications
Contact Arrangement —
K81A — SPST-NO
K81B — SPST-NC
Contact Form —
K81A — A
K81B — B
Test Voltage, DC or 60 Hz (Peak) —
11 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 10 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 5 A, 20 A or 30 A 1
Coil Hi-Pot (Vrms, 60 Hz) — N/A
Contact Resistance, Max. —
0.03 ohm
Operate Time, Max. — 10 ms
Release Time, Max. — 10 ms
Shock, 11ms, 1/2 Sine (Peak) —
30 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Ambient Temperature
Range — -55°C to +85°C
Mechanical Life
— 2 million cycles
Weight, Nominal —
56.7 g (2 oz.)
Notes:
1. PC pin versions carry 5 or 20
Amps, see part number at right.
Flying lead and panel versions
carry 30 Amp.
* Power terminal on 20 Amp version
is a larger diameter than on the
5 Amp version (.025 = 5 Amp,
.064 = 20 Amp)
Coil Data
Volts, Nominal DC 12 V 26.5 V 115 V
Pickup, Max. 8 Vdc 16 Vdc 80 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-50 Vdc
Coil Resistance (±10%) 70 Ω 290 Ω 4700 Ω
Ratings listed are for 25°C, sea level conditions
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
K81C Series Make & Break Load Switching — 10 kV Relays
Product Facts
n SPDT version of K81
n Vacuum dielectric for power
switching low current loads
n Flying lead version will
carry 10 Amps continuous
current
n PCB mount version will
carry 5 Amps continuous
current
Product Specifications
Contact Arrangement —
SPDT
Contact Form — C
Test Voltage, DC or 60 Hz (Peak) —
11 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 10 kV
Continuous Carry Current, Max. —
DC or 60 Hz — See Note 1
Coil Hi-Pot (Vrms, 60 Hz) — N/A
Contact Resistance, Max. —
0.05 ohm
Operate Time, Max. — 10 ms
Release Time, Max. — 10 ms
Shock, 11ms, 1/2 Sine (Peak) —
30 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Ambient Temperature
Range — -55°C to +85°C
Mechanical Life — 2 million cycles
Weight, Nominal —
70.87 g (2.5 oz.)
Note:
1. 5 Amp carry for PC pin versions.
30 Amp carry for flying lead
versions.
Coil Data
Volts, Nominal DC 12 V 26.5 V 115 V
Pickup, Max. 8 Vdc 16 Vdc 80 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-50 Vdc
Coil Resistance (±10%) 70 Ω 290 Ω 4700 Ω
Ratings listed are for 25°C, sea level conditions
Ordering Information
Sample Part Number K81 C 3 3 5
Series:
Contact Form:
C = SPDT
Coil Voltage:
2 = 12 Vdc, PC Board
3 = 26.5 Vdc, PC Board
5 = 115 Vdc, PC Board
High Voltage Connections:
3 = PCB Solder Connection
4 = Flying Leads
Mounting:
5 = PC Board
KILOVAC
High Voltage Relays
7
PAGE 85
KILOVAC High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
K43 Series Make & Break Load Switching — 10 kV Relays
K43A and K43B
Product Facts for
K43A and K43B
n 10 kV, 25 Amps continuous
current relay
n RF ratings to 32 MHz
n Vacuum dielectric for power
switching low current loads
n 2 million cycle mechanical
life
n QPL versions available,
M83725/17 & M83725/10
K43C
Product Facts for K43C
n SPDT version of K43
n Vacuum dielectric for power
switching low current loads
n Flange mounting available
n Carries 10 Amps at 32 MHz
n Meets requirements of
MIL-R-83725
n QPL version available,
M83725/16
Product Specifications for
K43A, K43B and K43C
Contact Arrangement —
K43A — SPST-NO
K43B — SPST-NC
K43C — SPDT
Contact Form —
K43A — A
K43B — B
K43C — C
Test Voltage, DC or 60 Hz (Peak) —
11 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 10 kV
2.5 MHz — 7 kV
16 MHz — 6 kV
32 MHz — 4 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 25 A
2.5 MHz — 20 A
16 MHz — 13 A
32 MHz — 10 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts — 1.2 pF
Open Contacts to Ground — 1.2 pF
Contact Resistance, Max. —
0.02 ohm
Operate Time, Max. — 10 ms
Release Time, Max. — 10 ms
Shock, 11ms, 1/2 Sine (Peak) —
50 g
Vibration —
Peak — 10 g (55 to 2000 Hz)
Operating Ambient Temperature
Range — -55°C to +125°C
Mechanical Life — 2 million cycles
Weight, Nominal —
28.35 g (1 oz.)
Coil Data
Volts, Nominal DC 12 V 26.5 V 115 V
Pickup, Max. 8 Vdc 16 Vdc 80 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-50 Vdc
Coil Resistance (±10%) 70 Ω 290 Ω 4700 Ω
Ratings listed are for 25°C, sea level conditions
Ordering Information
Sample Part Number K43 A 3 3 4
Series:
Contact Form:
A = SPST-NO B = SPST-NC C = SPDT
Coil Voltage:
2 = 12 Vdc, Bus Wire 3 = 26.5 Vdc, Bus Wire
5 = 115 Vdc, Bus Wire 7 = 12 Vdc, Turret Terminal*
8 = 26.5 Vdc, Turret Terminal*
9 = 115 Vdc, Turret Terminal*
High Voltage Connections:
3 = Solder Connection
Mounting*:
2 = Flanged 4 = Standard
* See page 7-87 for turret
terminal dimensions and
mounting methods.
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
K43 Series Make & Break Load Switching — 10 kV Relays (Continued)
KILOVAC K43P
Make & Break Load
Switching
Product Facts for K43P
n High power rating; 24 Amps
DC continuous current carry
n Vacuum dielectric for power
switching low current loads
n Low power consumption
n Fast operating: 5 millisecond
operate time
n Meets requirements of
MIL-R-83725
KILOVAC K43R
Make & Break Load
Switching
Product Facts for K43R
n Single pole, double throw
contacts with latching
actuator
n Vacuum dielectric for power
switching low current loads
n Carries 6 Amps at 32 MHz
n Meets requirements of
MIL-R-83725
Product Specifications for
K43P and K43R
Contact Arrangement —
K43P — SPST-Latching
K43R — SPDT-Latching
Contact Form —
K43P — P
K43R — R
Test Voltage, DC or 60 Hz (Peak) —
11 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 10 kV
2.5 MHz — 7 kV
16 MHz — 6 kV
32 MHz — 4 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 24 A
2.5 MHz — 16 A
16 MHz — 9 A
32 MHz — 6 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts — 1.2 pF
Open Contacts to Ground — 1.2 pF
Contact Resistance, Max. —
0.02 ohm
Operate Time, Max. —
K43P — 5 ms
K43R — 6 ms
Release Time, Max. — N/A
Shock, 11ms, 1/2 Sine (Peak) —
30 g
Vibration —
Peak — 7 g (55 to 2000 Hz)
Operating Ambient Temperature
Range — -55°C to +125°C
Mechanical Life — 1 million cycles
Weight, Nominal —
28.35 g (1 oz.)
* See page 7-87 for mounting
methods.
Coil Data
Volts, Nominal 26.5 Vdc
Latch & Reset, Max. 16 Vdc
Dropout N/A
Coil Resistance (±10%) 80 Ω
Ratings listed are for 25°C, sea level
conditions
Ordering Information
Sample Part Number K43 P 3 3 4
Series:
Contact Form:
P = SPST-Latching R = SPDT-Latching
Coil Voltage:
3 = 26.5 Vdc, Bus Wire
High Voltage Connections:
3 = Solder Connection
Mounting:
2 = Flanged 4 = Standard
KILOVAC
High Voltage Relays
7
PAGE 87
KILOVAC High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
H-14/16 Series Make & Break Load Switching — 12 kV Relays
H-14
Product Facts for H-14
n Double pole, double throw
contacts
n Vacuum dielectric for power
switching low current loads
n 30 Amps DC continuous
current rating
n Corona shield high voltage
terminals available
n Meets requirements of
MIL-R-83725
Product Specifications for
H-14 and H-16
Contact Arrangement — DPDT
Contact Form — 2C
Test Voltage, DC or 60 Hz (Peak) —
15 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 12 kV
2.5 MHz — 10 kV
16 MHz — 8 kV
32 MHz — 5 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 30 A
2.5 MHz — H-14 — 15 A
H-16 — 10 A
16 MHz — H-14 — 10 A
H-16 — 6 A
32 MHz — H-14 — 8 A
H-16 — 4 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts — 1 pF
Open Contacts to Ground — 2.5 pF
Contact Resistance, Max. —
H-14 — 0.015 ohm
H-16 — 0.03 ohm
Operate Time, Max. — 20 ms
Release Time, Max. — 20 ms
Shock, 11ms, 1/2 Sine (Peak) —
20 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Ambient Temperature
Range — -55°C to +125°C
Mechanical Life
(Operations x 106) —
H-14 — 1 million cycles
H-16 — 500,000 cycles
Weight, Nominal —
H-14 — 226.8 g (8 oz.)
H-16 — 170.1 g (6 oz.)
H-16
Product Facts for H-16
n 12 kV rating; isolates 5 kV at
32 MHz
n Vacuum dielectric for power
switching low current loads
n Double pole, double throw
contacts
n Widely used as a transmit/
receive switch
n Meets requirements of
MIL-R-83725
Ordering Information
Sample Part Number H- 14 /12Vdc
Series:
Model:
14 16
Coil Voltage:
Blank = 26.5 Vdc
/12Vdc = 12 Vdc
/115Vdc = 115 Vdc
Coil Data
Nominal Volts DC 12 Vdc 26.5 Vdc 115 Vdc
Pickup, Max. 8 Vdc 16 Vdc 80 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-50 Vdc
Coil Resistance (±10%) 24 Ω 120 Ω 2000 Ω
Ratings listed are for 25°C, sea level conditions
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
H-8 Make & Break Load Switching — 15 kV Relays
Product Facts
n Single pole, double throw
contacts
n Vacuum dielectric for power
switching low current loads
n 30 Amps DC continuous
current rating
n Corona shield high voltage
terminals available
n Meets requirements of
MIL-R-83725
Product Specifications
Contact Arrangement —
SPDT
Contact Form — C
Test Voltage, DC or 60 Hz (Peak) —
20 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 15 kV
2.5 MHz — 12 kV
16 MHz — 10 kV
32 MHz — 5 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 15 A RMS
2.5 MHz — 10 A RMS
16 MHz — 6 A RMS
32 MHz — 4 A RMS
Coil Hi-Pot (Vrms, 60 Hz) — 500 A RMS
Contact Capacitance —
Between Open Contacts — 1 pF
Open Contacts to Ground — 1.5 pF
Contact Resistance, Max. —
0.015 ohm
Operate Time, Max. — 15 ms
Release Time, Max. — 15 ms
Shock, 11ms, 1/2 Sine (Peak) —
30 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Temperature Range —
-55°C to +125°C
Mechanical Life — 1 million cycles
Weight, Nominal —
85 g (3 oz.)
Coil Data
Volts, Nominal DC 12 V 26.5 V 115 V
Pickup, Max. 8 Vdc 16 Vdc 80 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-50 Vdc
Coil Resistance (±10%) 60 Ω 265 Ω 3500 Ω
KILOVAC
High Voltage Relays
7
PAGE 89
KILOVAC High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KC Series Make & Break Load Switching — 15 kV Relays
KC-14
KC-18
Product Facts for
KC-14 and KC-18
n Specifically designed for
load switching applications
n Can power switch and
isolate loads
n Replaces KILOVAC KC-8 and
KC-12
n Meets requirements of
MIL-R-83725
Product Specifications for
KC-14 and KC-18
Contact Arrangement — SPDT
Contact Form — C
Test Voltage, DC or 60 Hz (Peak) —
17 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 15 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 30 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts — 0.5 pF
Open Contacts to Ground — 1 pF
Contact Resistance, Max. —
0.025 ohm
Operate Time, Max. — 15 ms
Release Time, Max. — 9 ms
Shock, 11ms, 1/2 Sine (Peak) —
50 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Ambient Temperature
Range — -55°C to +125°C
Mechanical Life — 1 million cycles
Weight, Nominal — 85 g (3 oz.)
Coil Data
Volts, Nominal DC 12 V 26.5 V 115 V
Pickup, Max. 8 Vdc 16 Vdc 80 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-50 Vdc
Coil Resistance (±10%) 48 Ω 180 Ω 2900 Ω
Ratings listed are for 25°C, sea level conditions
*Hot Switching, Resistive Load Life
Voltage Current Load Life
Operations
330 Vdc 17 Amps 10,000
330 Vdc 5 Amps 100,000
5,000 Vdc 2 Amps 100,000
10,000 Vdc 1 Amps 50,000
* Ratings are for normally open contacts only. No testing has been performed
on normally closed contacts.
Ordering Information
Sample Part Number KC- 18 /12Vdc
Series:
Model:
14 18
Coil Voltage:
Blank = 26.5 Vdc /12Vdc = 12 Vdc /115Vdc = 115 Vdc
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KC Series Make & Break Load Switching — 15 kV Relays (Continued)
Ordering Information
Sample Part Number KC- 2 /12Vdc
Series:
Model:
2 8 11 12
Coil Voltage:
Blank = 26.5 Vdc /12Vdc = 12 Vdc /115Vdc = 115 Vdc
KC-2
No Load Switching
Product Facts
n Vacuum dielectric for low
and stable contact resistance
n Carries 50 Amps at DC;
10 Amps at 32 MHz
n Not designed for power
switching
KC-8
Product Facts for KC-8
n Not recommended for new
design. See KC-14 on page
7-82 for replacement.
Product Specifications for
KC-2, KC-8, KC-11 and KC-12
Contact Arrangement — SPDT
Contact Form — C
Test Voltage, DC or 60 Hz (Peak) —
17 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 15 kV
2.5 MHz — KC-2 and KC-11 — 12 kV
16 MHz — KC-2 and KC-11 — 9 kV
32 MHz — KC-2 and KC-11 — 7 kV
Continuous Carry Current, Max. —
DC or 60 Hz — KC-2 and KC-11 — 50 A
KC-8 and KC-12 — 30 A
2.5 MHz — KC-2 and KC-11 — 30 A
16 MHz — KC-2 and KC-11 — 17 A
32 MHz — KC-2 and KC-11 — 10 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts — 0.5 pF
Open Contacts to Ground — 1 pF
Contact Resistance, Max. —
KC-2 and KC-11 — 0.012 ohm
KC-8 and KC-12 — 0.025 ohm
Operate Time, Max. — 15 ms
Release Time, Max. — 9 ms
Shock, 11ms, 1/2 Sine (Peak) —
50 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Ambient Temperature
Range — -55°C to +125°C
Mechanical Life — 1 million cycles
Weight, Nominal —
85 g (3 oz.)
KC-11
No Load Switching
Product Facts
n Threaded base version of
KC-2
n Vacuum dielectric for low
leakage current applications
KC-12
Product Facts
n Not recommended for new
design. See KC-18 on page
7-67 for replacement.
n Vacuum dielectric for power
switching low current loads
Coil Data
Nominal Volts DC 12 Vdc 26.5 Vdc 115 Vdc
Pickup, Max. 8 Vdc 16 Vdc 80 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-50 Vdc
Coil Resistance (±10%)
KC-2 and KC-11 60 Ω 250 Ω 3500 Ω
KC-8 and KC-12 48 Ω 180 Ω 2900 Ω
Ratings listed are for 25°C, sea level conditions
KILOVAC
High Voltage Relays
7
PAGE 91
KILOVAC High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KC Series Make Only Load Switching — 15 kV Relays (Continued)
KC-15
Product Facts
n SF-6 gas-filled for power
switching on the “make”
n Long load life in capacitive
discharge
n Recommended for ESD
testing and safety interlock
applications
n Meets requirements of
MIL-R-83725
KC-16
Product Facts
n Threaded base version of
KC-15
n SF-6 gas-filled for power
switching on the “make”
n 15 kV rating
n Meets requirements of
MIL-R-83725
Product Specifications for
KC-15 and KC-16
Contact Arrangement — SPDT
Contact Form — C
Test Voltage, DC or 60 Hz (Peak) —
17 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 15 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 12 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts — N/A
Open Contacts to Ground — N/A
Contact Resistance, Max. —
1.0 ohm*
Operate Time, Max. — 15 ms
Release Time, Max. — 9 ms
Shock, 11ms, 1/2 Sine (Peak) —
50 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Ambient Temperature
Range — -55°C to +125°C
Mechanical Life — 1 million cycles
Weight, Nominal — 85 g (3 oz.)
Note:
* Contact resistance for gas-filled
relays measured 28 Vdc, 1 Amp
Coil Data
Volts, Nominal DC 12 V 26.5 V 115 V
Pickup, Max. 8 Vdc 16 Vdc 80 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-50 Vdc
Coil Resistance (±10%) 48 Ω 180 Ω 2900 Ω
Ratings listed are for 25°C, sea level conditions
Ordering Information
Sample Part Number KC- 15 /12Vdc
Series:
Model:
15
16
Coil Voltage:
Blank = 26.5 Vdc
/12Vdc = 12 Vdc
/115Vdc = 115 Vdc
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
H-26 Series Make & Break Load Switching — 15 kV Relays
Product Facts
n Highly reliable four pole
double throw relay
n Used to switch multiple
loads and for polarity
reversal
n Vacuum dielectric for power
switching low current loads
n Meets requirements of
MIL-R-83725
Product Specifications
Contact Arrangement — 4PDT
Contact Form — 4C
Test Voltage, DC or 60 Hz (Peak) —
17 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 15 kV
2.5 MHz — 12 kV
16 MHz — 10 kV
32 MHz — 7 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 30 A
2.5 MHz — 10 A
16 MHz — 6 A
32 MHz — 4 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts — 1 pF
Open Contacts to Ground — 2.5 pF
Contact Resistance, Max. —
0.02 ohm
Operate Time, Max. — 30 ms
Release Time, Max. — 30 ms
Shock, 11ms, 1/2 Sine (Peak) —
30 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Ambient Temperature
Range — -55°C to +125°C
Mechanical Life — 100,000 cycles
Weight, Nominal — 340 g (12 oz.)
Coil Data
Volts, Nominal DC 12 V 26.5 V 115 V
Pickup, Max. 8 Vdc 16 Vdc 80 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-50 Vdc
Coil Resistance (±10%) N/A 130 Ω 2100 Ω
Ratings listed are for 25°C, sea level conditions
Ordering Information
Sample Part Number H-26 /12Vdc
Model:
H-26
Coil Voltage:
Blank = 26.5 Vdc
/12Vdc = 12 Vdc
/115Vdc = 115 Vdc
KILOVAC
High Voltage Relays
7
PAGE 93
KILOVAC High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
H-19/17 Series Make & Break Load Switching — 20/25 kV Relays
H-19
Product Facts
n 20 kV operating voltage
n Vacuum dielectric and
tungsten contacts for power
switching low current loads
n Double pole, double throw
contacts
n Available with corona shield
connectors
n Meets requirements of
MIL-R-83725
Product Specifications for
H-19 and H-17
Contact Arrangement —
H-19 — DPDT
H-17 — SPDT
Contact Form —
H-19 — 2C
H-17 — C
Test Voltage, DC or 60 Hz (Peak) —
H-19 — 25 kV
H-17 — 30 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — H-19 — 20 kV
H-17 — 25 kV
2.5 MHz — H-19 — 15 kV
H-17 — 20 kV
16 MHz — H-19 — 10 kV
H-17 — 15 kV
32 MHz — H-19 — 7 kV
H-17 — 12 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 30 A
2.5 MHz — H-19 — 18 A
H-17 — 16 A
16 MHz — H-19 — 9 A
H-17 — 10 A
32 MHz — H-19 — 6 A
H-17 — 8 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts — 1 pF
Open Contacts to Ground — 2.5 pF
Contact Resistance, Max. —
0.015 ohm
Operate Time, Max. —
H-19 — 30 ms
H-17 — 25 ms
Release Time, Max. —
H-19 — 20 ms
H-17 — 25 ms
Shock, 11ms, 1/2 Sine (Peak) —
H-19 — 30 g
H-17 — 20 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Ambient Temperature
Range — -55°C to +125°C
Mechanical Life — 1 million cycles
Weight, Nominal —
H-19 — 241 g (8.5 oz.)
H-17 — 198.4 g (7 oz.)
H-17
Product Facts
n Will isolate 12 kV at 32 MHz
n Tungsten contacts suitable
for power switching low
current loads
n Available with corona shield
connectors
n Meets requirements of
MIL-R-83725
n QPL version available,
M83725/2
Coil Data
Nominal Volts DC 12 Vdc 26.5 Vdc 115 Vdc
Pickup, Max. 8 Vdc 16 Vdc 80 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-50 Vdc
Coil Resistance (±10%)
H-19 48 Ω 225 Ω 2100 Ω
H-17 24 Ω 120 Ω 2900 Ω
Ratings listed are for 25°C, sea level conditions
Ordering Information
Sample Part Number H- 17 /12Vdc
Series:
Model:
H-19
H-17
Coil Voltage:
Blank = 26.5 Vdc
/12Vdc = 12 Vdc
/115Vdc = 115 Vdc
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
K62 Series Make & Break Load Switching — 25 kV Relays
K62A and K62B
Product Facts
n 25 kV relay with flying leads
for ease of installation
n Vacuum dielectric and
tungsten contacts for power
switching low current loads
n Meets requirements of
MIL-R-83725
K62C
Product Facts
n SPDT version of K62
n Vacuum dielectric for power
switching low current loads
n Carries 18 Amps continuous
current
n Meets requirements of
MIL-R-83725
Product Specifications for
K62A, K62B and K62C
Contact Arrangement —
K62A — SPST-NO
K62B — STST-NC
K62C — SPDT
Contact Form —
K62A — A
K62B — B
K62C — C
Test Voltage, DC or 60 Hz (Peak) —
30 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 25 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 18 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Resistance, Max. —
0.50 ohm
Operate Time, Max. — 15 ms
Release Time, Max. — 15 ms
Shock, 11ms, 1/2 Sine (Peak) —
20 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Ambient Temperature
Range — -55°C to +85°C
Mechanical Life — 1 million cycles
Weight, Nominal — 340 g (12 oz.)
Coil Data
Volts, Nominal DC 12 V 26.5 V 115 V
Pickup, Max. 9 Vdc 18 Vdc 90 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-55 Vdc
Coil Resistance (±10%) 30 Ω 125 Ω 2400 Ω
Ratings listed are for 25°C, sea level conditions
Ordering Information
Sample Part Number K62 A 7 4 1
Series:
Contact Form:
A = SPST-NO B = SPST-NC C = SPDT
Coil Voltage:
7 = 12 Vdc, Turret Terminal
8 = 26.5 Vdc, Turret Terminal
9 = 115 Vdc, Turret Terminal
High Voltage Connections:
4 = Flying Leads, 12”
7 = Flying Leads, 72”
8 = Flying Leads, 36”
Mounting:
1 = Threaded
KILOVAC
High Voltage Relays
7
PAGE 95
KILOVAC High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KC-Series No Load Switching — 25 kV Relays
KC-20
Product Facts
n Rugged, high current carry
ceramic relay
n Carries 30 Amps at 32 MHz
n Copper contacts; not
designed for power
switching
n Meets requirements of
MIL-R-83725
Product Specifications for
KC-20 and KC-30
Contact Arrangement —
KC-20 — SPST-NO
KC-30 — SPST-NC
Contact Form —
KC-20 — X
KC-30 — Y
Test Voltage, DC or 60 Hz (Peak) —
KC-20 — 30 kV
KC-30 — 28 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — KC-20 — 28 kV
KC-30 — 25 kV
2.5 MHz — 22 kV
16 MHz — KC-20 — 12 kV
KC-30 — 10 kV
32 MHz — KC-20 — 10 kV
KC-30 — 9 kV
Continuous Carry Current, Max. —
DC or 60 Hz — KC-20 — 110 A
KC-30 — 55 A
2.5 MHz — KC-20 — 60 A
KC-30 — 30 A
16 MHz — KC-20 — 40 A
KC-30 — 20 A
32 MHz — KC-20 — 30 A
KC-30 — 15 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts — 2.5 pF
Open Contacts to Ground — 2.5 pF
Contact Resistance, Max. —
KC-20 — 0.005 ohm
KC-30 — 0.01 ohm
Operate Time, Max. — 18 ms
Release Time, Max. —
KC-20 — 10 ms
KC-30 — 20 ms
Shock, 11ms, 1/2 Sine (Peak) —
30 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Ambient Temperature
Range — -55°C to +125°C
Mechanical Life — 2 million cycles
Weight, Nominal —
340 g (12 oz.)
KC-30
Product Facts
n Normally closed version of
KC-20
n Carries 55 Amps DC
n Vacuum dielectric for low
leakage current applications
Coil Data
Volts, Nominal DC 12 V 26.5 V 115 V
Pickup, Max. 8 Vdc 16 Vdc 80 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-50 Vdc
Coil Resistance (±10%) 24 Ω 120 Ω 2000 Ω
Ratings listed are for 25°C, sea level conditions
Ordering Information
Sample Part Number KC- 20 /12Vdc
Series:
Model:
KC-20
KC-30
Coil Voltage:
Blank = 26.5 Vdc
/12Vdc = 12 Vdc
/115Vdc = 115 Vdc
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KC-Series — 25 kV Relays
KC-22, KC-32
Make & Break Load
Switching
Product Facts for KC-22
n Tungsten contacts for power
switching
Product Facts for KC-32
n Normally closed version of
KC-22
n Vacuum dielectric for power
switching low current loads
Product Specifications for
KC-22, KC-32, KC-28 & KC-38
Contact Arrangement —
KC-22 and KC-28 — SPST-NO
KC-32 and KC-38 — SPST-NC
Contact Form —
KC-22 and KC-28 — X
KC-32 and KC-38 — Y
Test Voltage, DC or 60 Hz (Peak) —
28 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 25 kV
Continuous Carry Current, Max. —
DC or 60 Hz — KC-22 — 65 A
KC-32 — 45 A
KC-28 — 30 A
KC-38 — 15 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts —
KC-22 and KC-32 — 2.5 pF
Open Contacts to Ground —
KC-22 and KC-32 — 2.5 pF
Contact Resistance, Max. —
KC-22 — 0.005 ohm
KC-32 — 0.01 ohm
KC-28 — 1.0 ohm*
KC-38 — 1.0 ohm*
Operate Time, Max. — 18 ms
Release Time, Max. —
KC-22 and KC-28 — 10 ms
KC32 and KC-38 — 20 ms
Shock, 11ms, 1/2 Sine (Peak) —
30 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Ambient Temperature
Range — -55°C to +125°C
Mechanical Life — 2 million cycles
Weight, Nominal — 340 g (12 oz.)
KC-28, KC-38
Make Only Load Switching
Product Facts for KC-28
n SF-6 gas-filled for capacitive
discharge and “make only”
applications
n Capable of switching 2000
Amps peak capacitive
discharge for 400
nanoseconds
Product Facts for KC-38
n Normally closed version of
KC-28
n SF-6 gas-filled for capacitive
discharge and “make only”
applications
Coil Data
Volts, Nominal DC 12 V 26.5 V 115 V
Pickup, Max. 8 Vdc 16 Vdc 80 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-50 Vdc
Coil Resistance (±10%) 24 Ω 120 Ω 2000 Ω
Ratings listed are for 25°C, sea level conditions
Ordering Information
Sample Part Number KC- 22 /12Vdc
Series:
Model:
KC-22 KC-32 KC-28 KC-38
Coil Voltage:
Blank = 26.5 Vdc /12Vdc = 12 Vdc /115Vdc = 115 Vdc
KILOVAC
High Voltage Relays
7
PAGE 97
KILOVAC High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
H-23/24 Series Make & Break Load Switching — 30 kV Relay
(Not recommended for new
designs)
Product Facts
n See K61 or K62 series for
latest generation products
n Vacuum dielectric for power
switching low current loads
Product Specifications
Contact Arrangement —
H-23 — SPST-NC
H-24 — SPST-NO
Contact Form —
H-23 — B
H-24 — A
Test Voltage, DC or 60 Hz (Peak) —
35 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 30 kV
2.5 MHz — 24 kV
16 MHz — 18 kV
32 MHz — 7 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 30 A
2.5 MHz — 20 A
16 MHz — 12 A
32 MHz — 7 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts — N/A
Open Contacts to Ground — N/A
Contact Resistance, Max. —
0.015 ohm
Operate Time, Max. — 30 ms
Release Time, Max. — 20 ms
Shock, 11ms, 1/2 Sine (Peak) —
20 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Ambient Temperature
Range — -55°C to +125°C
Mechanical Life — 1 million cycles
Weight, Nominal — 198.4 g (7 oz.)
Coil Data
Volts, Nominal DC 12 V 26.5 V 115 V
Pickup, Max. 8 Vdc 16 Vdc 80 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-50 Vdc
Coil Resistance (±10%) 24 120 Ω 2000 Ω
Ratings listed are for 25°C, sea level conditions
Ordering Information
Sample Part Number H- 23 /12Vdc
Series:
Model:
H-23
H-24
Coil Voltage:
Blank = 26.5 Vdc
/12Vdc = 12 Vdc
/115Vdc = 115 Vdc
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
KP61 Series — 35 kV Relays
Product Facts
n SF-6 gas-filled relay is
excellent for capacitive
discharge applications
n Widely used in test
equipment and medical
instruments
n Fully operable in air
and suitable for adverse
environments
n Contact forms A, B & C
n 35 kV rating in compact,
durable package
n Lower cost version of K61
series
Product Specifications
Contact Arrangement/Form —
SPST-NO / A
SPST-NC / B
SPDT / C
Test Voltage, DC or 60 Hz (Peak) —
40 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 35 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 10 A
Contact Resistance, Max. —
1.0Ω
Shock, 11ms, 1/2 Sine (Peak) —
20 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Ambient Temperature
Range — -55°C to +85°C
Mechanical Life — 1 million cycles
Weight, Nominal — 297.7g (10.5
oz.)
Coil Data
Volts, Nominal DC 12 V 26.5 V 115 V
Pickup, Max. 9 Vdc 18 Vdc 90 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-50 Vdc
Coil Resistance (±10%) 30 Ω 125 Ω 2000 Ω
Ratings listed are for 25°C, sea level conditions
Ordering Information
Sample Part Number KP61 C 8 4 1
Series:
Contact Form:
A = SPST-NO B = SPST-NC C = SPDT
Coil Voltage:
7 = 12 Vdc, Turret Terminal
8 = 26.5 Vdc, Turret Terminal
9 = 115 Vdc, Turret Terminal
High Voltage Connections:
4 = Flying Leads, 12”
5 = Flying Leads, 72”
6 = Flying Leads, 36”
Mounting:
1 = Threaded
KILOVAC
High Voltage Relays
7
PAGE 99
KILOVAC High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
K60 Series Make Only Load Switching — 35 kV Relays
K60C (35 kV)*
Product Facts
n 35 kV rating when operated
in oil or potting
n Smallest 35 kV rated relay
available
* Customer must isolate high
voltage terminals using suit-
able dielectric such as oil or
potting
Product Specifications
Contact Arrangement — SPDT
Contact Form — C
Test Voltage, DC or 60 Hz (Peak) —
37 kV**
Rated Operating Voltage (Peak) —
DC or 60 Hz — 35 kV**
Continuous Carry Current, Max. —
DC or 60 Hz — 10 A RMS
Coil Hi-Pot (Vrms, 60 Hz) — 500 A RMS
Contact Resistance, Max. — N/A
Operate Time, Max. — 15 ms
Release Time, Max. — 15 ms
Shock, 11ms, 1/2 Sine (Peak) —
20 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Ambient Temperature
Range — -55°C to +85°C
Mechanical Life — 1 million cycles
Weight, Nominal — 93.6 g (3.3 oz.)
Note:
** 37 kV test voltage, 35 kV operate
voltage when operated in oil.
Coil Data
Volts, Nominal DC 12 V 26.5 V 115 V
Pickup, Max. 9 Vdc 18 Vdc 90 Vdc
Coil Resistance (±10%) 30 Ω 125 Ω 2400 Ω
Ratings listed are for 20°C, sea level conditions
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
K61 Series Make Only Load Switching — 35 kV Relays
K61A and K61B
Product Facts for
K61A and K61B
n SF-6 gas-filled relay
excellent for capacitive
discharge applications
n Widely used in test
equipment and medical
instruments
n Fully operable in air
and suitable for adverse
environments
K61C
Product Facts for K61C
n 35 kV rating in compact,
durable package
n SF-6 gas-filled relay
excellent for capacitive
discharge applications
n SPDT version of K61
Product Specifications for
K61A, K61B and K61C
Contact Arrangement —
K61A — SPST-NO
K61B — STST-NC
K61C — SPDT
Contact Form —
K61A — A
K61B — B
K61C — C
Test Voltage, DC or 60 Hz (Peak) —
40 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 35 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 10 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Resistance, Max. —
1.0 ohm*
Operate Time, Max. — 15 ms
Release Time, Max. — 15 ms
Shock, 11ms, 1/2 Sine (Peak) —
20 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Ambient Temperature
Range — -55°C to +85°C
Mechanical Life — 1 million cycles
Weight, Nominal — 340 g (12 oz.)
Note:
* Contact resistance for gas-filled
relays measured at 28 Vdc, 1 Amp
Coil Data
Volts, Nominal DC 12 V 26.5 V 115 V
Pickup, Max. 9 Vdc 18 Vdc 90 Vdc
Dropout .5-5 Vdc 1-10 Vdc 5-50 Vdc
Coil Resistance (±10%) 30 Ω 125 Ω 2000 Ω
Ratings listed are for 25°C, sea level conditions
Ordering Information
Sample Part Number K61 A 7 4 1
Series:
Contact Form:
A = SPST-NO B = SPST-NC C = SPDT
Coil Voltage:
7 = 12 Vdc, Turret Terminal
8 = 26.5 Vdc, Turret Terminal
9 = 115 Vdc, Turret Terminal
High Voltage Connections:
4 = Flying Leads, 12”
7 = Flying Leads, 72”
8 = Flying Leads, 36”
Mounting:
1 = Threaded
KILOVAC
High Voltage Relays
7
PAGE 101
KILOVAC High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
K64 & H-25 Series — 50 kV Relays
K64C
Make Only Load Switching
Product Facts for K64C
n SF-6 gas-filled relay ideal
for high voltage isolation
or “make only” power
switching
n 50 kV rating in compact
package
n High voltage leads and
encapsulation allow full
operation in air
H-25
Make & Break Load
Switching
Product Facts for H-25
n Vacuum relay provides low
contact resistance
n Vacuum dielectric for power
switching low current loads
Product Specifications for
K64C and H-25
Contact Arrangement — SPDT
Contact Form — C
Test Voltage, DC or 60 Hz (Peak) —
K64C — 55 kV
H-25 — 60 kV
Rated Operating Voltage (Peak) —
DC or 60 Hz — 50 kV
Continuous Carry Current, Max. —
DC or 60 Hz — K64C — 10 A
H-25 — 30 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Resistance, Max. —
K64C — 1.0 ohm*
H-25 — 0.015 ohm
Operate Time, Max. —
K64C — 15 ms
H-25 — 60 ms
Release Time, Max. —
K64C — 15 ms
H-25 — 60 ms
Shock, 11ms, 1/2 Sine (Peak) —
K64C — 10 g
H-25 — 15 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Ambient Temperature
Range — -55°C to +85°C
Mechanical Life —
K64C — 1 million cycles
H-25 —500,000 cycles
Weight, Nominal —
K64C — 340 g (12 oz.)
H-25 — 850.5 g (30 oz.)
Note:
* Contact resistance for gas-filled
relays measured at 28 Vdc, 1 Amp
Coil Data
K64C H-25
Nominal Volts DC 26.5 Vdc 26.5 Vdc
Pickup, Max. 18 Vdc 16 Vdc
Dropout 1-10 Vdc 1-10 Vdc
Coil Resistance (±10%) 80 Ω 120 Ω
Ratings listed are for 25°C, sea level conditions
Ordering Information
Sample Part Number K64 C 8 4 1
Series:
Contact Form:
C = SPDT
Coil Voltage:
8 = 26.5 Vdc, Turret Terminal
High Voltage Connections:
4 = Flying Leads, 12”
7 = Flying Leads, 72”
8 = Flying Leads, 36”
Mounting:
1 = Threaded
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
K70 Series Make Only Load Switching — 70 kV Relays
K70A and K70B
Product Facts
n New, small, compact 70 kV
relay package
n SF-6 gas-filled for
capacitive discharge and
high voltage isolation
applications
n Suitable for charging and
discharging of high voltage
capacitors
n Safe for use in adverse
environments
K70C
Product Facts
n SPDT version of K70A
n SF-6 gas-filled for
capacitive discharge and
high voltage isolation
applications
n Suitable for charging and
discharging of high voltage
capacitors
Product Specifications for
K70A, K70B and K70C
Contact Arrangement —
K70A — SPST-NO
K70B — SPST-NC
K70C — SPDT
Contact Form —
K70A — A
K70B — B
K70C — C
Test Voltage, DC or 60 Hz (Peak) —
75 kV
Rated Operating Voltage (Peak) —
DC — 70 kV
60 Hz RMS — 30 kV
Continuous Carry Current, Max. —
DC or 60 Hz — 10 A
Coil Hi-Pot (Vrms, 60 Hz) — 500 A
Contact Capacitance —
Between Open Contacts — N/A
Open Contacts to Ground — N/A
Contact Resistance, Max. —
2.0 ohm*
Operate Time, Max. — 20 ms
Release Time, Max. — 15 ms
Shock, 11ms, 1/2 Sine (Peak) —
20 g
Vibration —
Peak — 10 g (55 to 500 Hz)
Operating Ambient Temperature
Range — 0°C to +85°C
Mechanical Life —500,000 cycles
Weight, Nominal —
510.3 g (18 oz.)
Note:
* Contact resistance for gas-filled
relays measured at 28 Vdc, 1 Amp
Coil Data
Volts, Nominal 26.5 Vdc
Pickup, Max. 22 Vdc
Dropout 1-10 Vdc
Coil Resistance (±10%) 75 Ω
Ratings listed are for 25°C, sea level
conditions
Ordering Information
Sample Part Number K70 A 8 4 1
Series:
Contact Form:
A = SPST-NO B = SPST-NC C = SPDT
Coil Voltage:
8 = 26.5 Vdc, Turret Terminal
High Voltage Connections:
4 = Flying Leads, 12”
7 = Flying Leads, 72”
8 = Flying Leads, 36”
Mounting:
1 = Threaded
KILOVAC
High Voltage Relays
7
PAGE 103
KILOVAC High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
Mounting Methods
KILOVAC “stacked ceramic”
series relays can be easily
mounted in any of the
several ways shown below.
The relay base should
be mounted to a ground
potential for high voltage
applications. KILOVAC
relays are not position
sensitive and can be
mounted in any orientation.
Optional Coil Turret Terminals
for PD5, PD10; K41, K43 Types
Figure 1.
Standard Flange Mounting
Figure 2.
Optional Flange Mounting for K44
Figure 3.
Optional Flange Mounting for
PD5, PD10; K40, K41, K43 and K45 types
Figure 4.
Strap Mounting
Figure 6. Adel Fasteners
9320010 (stainless & silicone)
9320002 (carbon steel & neoprene)
Spring Clip Mounting
Figure 5. Seastrom Manufacturing
(800/447-3927 or 208/737-4300)
Part Number 4502-53-50-2N or sim-
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
Special Connectors
A number of KILOVAC
relays are available with
special, anti-corona high
voltage connectors. Refer
to the chart to determine
if high voltage connectors
are available for your model
relay. These connectors can
be ordered separately, by
part number, or at the same
time you order your relays
(for “H: relays only) by
simply adding the letter
“C” to the part number.
For instance, if you wish to
purchase an H-8 relay with
special connectors, you
should order an “H-8C”.
If you already have an H-8,
you can order three Part
Number 0510 connectors
and install them yourself
by removing the standard
solder lugs and carefully
installing the connectors so
as not to damage the glass-
to-metal seals.
Connectors for EV250-1A, 1B, 2A & 2B
TE supplies a connector with 7 leads attached. Order Part Number 2005, Part Number
1618004-1.
Optional High Voltage Connectors
Relay Model Connector Part Number
H-8
H-14
H-16 0510
H-19
H-26
H-17
H-23 1886
H-24
EV250-1A
EV250-1B
EV250-2A 2005
EV250-2B
EV250-8A
EV250-8B
EV250-5A 2625
KC-2, KC-8
KC-11, KC-12 6822
KC-15, KC-16
KC-14, KC-18
KILOVAC
High Voltage Relays
7
PAGE 105
KILOVAC High Voltage Relays
For factory-direct application assistance,
dial 800-253-4560, ext. 2055, or
805-220-2055.
Special Connectors (Continued)
AC Coil Operation
All TE KILOVAC relays are supplied with a DC coil. If you wish to operate the relay with AC,
you may order a bridge rectifier as Part Number 0260.
Bus Bar Connector Option for EV, LEV, CAP and MAP Products
Standard Lug Connectors
Relay Model Connector Part Number
H-18 0575
H-17 1447
KM-13 6810
H-14
H-16 8488
H-19
H-26
.900
(22.9)
1.460
(37.1)
2.26
(57.4)
.386
(9.8)
.250
(6.3)
.250
(6.3)
Ø
.70
(17.78)
Ø
Ø
2XR .25 (6.3)
45˚ x .06 Chamfer
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
Application Notes for EV/LEV Contactors
Introduction - Product Capabilities and Typical
Applications
TE KILOVAC EV and LEV contactors are designed to be
the highest performance, smallest and lightest weight,
sealed High Voltage contactors in the industry. With current
carrying capability of up to 500A and power switching up to
200kW, they are used in a variety of industrial, marine, auto-
motive, and commercial applications. Primarily designed to
switch resistive loads,they can be used in a variety of circuit
applications bearing in mind a few important considerations.
This application note focuses on a few of the more common
circuit configurations, and what to consider when selecting,
installing and using the contactors.
1. Installation
EV/LEV contactors can be mounted in any orientation,
and due to the nature of their hermetic seal and isolated
enclosure, can be mounted in close proximity to other
equipment. However, care must be taken with regard to
the termination of the power cables to the main terminals.
It is important that the main power connection lugs are
mated directly to the terminal seats. Be sure that the
hardware stackup is in the proper order, and that washers
and other spacers are not placed between the lug and
terminal seat. Extraneous connection resistance can cause
considerable power dissipation and terminal heating at high
current carry.
Refer to Figure 1 and Table I for the recommended
hardware stackup and torque.
Use the same guidelines and torque maximum values for
stud terminal contactors as well.
2. Coils, Drive Circuits and Coil Economizing
Since the power required to close the contacts is generally
much greater than the required holding power, many
KILOVAC contactors can be packaged with low-profile coils
that utilize either an electronic economizer (switchmode
PWM), or mechanical cut-throat economizer. The
economizer lets-through the higher power required for
contact closure, then reduces the power for holding,
greatly reducing the coil power consumption and heating.
These circuits are packaged with the contactor, and in
most cases include coil suppression components as well.
For customers who wish to provide their own circuitry,
TE can provide suggestions for driving the coils of all
versions of contactors. Single coil, uneconomized products
are also available in the LEV product line. These coils are
designed to operate at nominal power over all specified volt-
age and temperature ranges withouteconomizing
circuitry. DC Coils up to 400Vdc and AC coils with
integrated converters are available up to 240Vac.
3. Load Types and Power Switching
Recommendations
In general, all EV/LEV contactors are designed primarily
for connection and interruption of resistive loads and
slightly inductive loads (L/R<1ms). High currents (up to
2000A) can be interrupted in case of circuit faults, and
high continuous currents upwards of 500A can be
maintained through closed contacts. Some important
points to consider are:
a. Closing into current spikes due to uncharged filter
capacitors. Capacitors should be pre-charged
whenever possible to avoid excessive contact erosion
and nuisance welds. Keep inrush current spikes
below 650A at all times. Care should also be taken
when considering other high-inrush loads such as
lamps or motors.
b. Large current spikes through closed contacts. Large
current spikes through closed contacts in excess of
3000A can sometimes cause spot welding or contact
levitation.
c. Circuit inductance. Contactor break-arcs generally
last as long as it takes to dissipate the stored inductive
energy of the load (t (arc) = 1.1*L/R).
Longer arcs due to circuit inductance can accelerate
contact wear, and in extreme cases, can cause contactor
failure. TE recommends that the time constant of the load
be less than 1ms for safe operation and maximum life.
Contactor life is a function of the power level switched.
Higher make/break currents erode contact materials
faster and accelerate loss of dielectric withstanding
between the open contacts. Figure 2 can be used as a
guideline for estimating product life at a given load.
Table I
THREAD
ENGAGEMENT(turns)
TORQUE
Less than 5 Use longer fastener
5 TO 7 7.9 Nm (70 in-lb) MAX
7 TO 8 9.0 Nm (80 in-lb) MAX
8 TO 11
9.0 Nm (80 in-lb)
11 Nm (100 in-lb) MAX
Mounting Feet (all) 1.7-3.3 Nm (30-35 in-lb)
Figure 1
Main Terminal Hardware Installation
Bolt
Lock Washer
Flat Washer
Lug
Lug
Terminal
Conductors
Thread
Engagement
Figure 2
Life Cycles vs. Power Switched
Figure 3
Recommended Conductor Sizes
Table I
THREAD
ENGAGEMENT(turns)
TORQUE
Less than 5 Use longer fastener
5 TO 7 7.9 Nm (70 in-lb) MAX
7 TO 8 9.0 Nm (80 in-lb) MAX
8 TO 11
9.0 Nm (80 in-lb)
11 Nm (100 in-lb) MAX
Mounting Feet (all) 1.7-3.3 Nm (30-35 in-lb)
Figure 1
Main Terminal Hardware Installation
Bolt
Lock Washer
Flat Washer
Lug
Lug
Terminal
Conductors
Thread
Engagement
Figure 2
Life Cycles vs. Power Switched
Figure 3
Recommended Conductor Sizes
Figure 1
Main Terminal Hardware Installation
Table I
KILOVAC
High Voltage Relays
7
PAGE 107
KILOVAC High Voltage Relays
Application Notes for EV/LEV Contactors (Continued)
Table I
THREAD
ENGAGEMENT(turns)
TORQUE
Less than 5 Use longer fastener
5 TO 7 7.9 Nm (70 in-lb) MAX
7 TO 8 9.0 Nm (80 in-lb) MAX
8 TO 11
9.0 Nm (80 in-lb)
11 Nm (100 in-lb) MAX
Mounting Feet (all) 1.7-3.3 Nm (30-35 in-lb)
Figure 1
Main Terminal Hardware Installation
Bolt
Lock Washer
Flat Washer
Lug
Lug
Terminal
Conductors
Thread
Engagement
Figure 2
Life Cycles vs. Power Switched
Figure 3
Recommended Conductor Sizes
Table I
THREAD
ENGAGEMENT(turns)
TORQUE
Less than 5 Use longer fastener
5 TO 7 7.9 Nm (70 in-lb) MAX
7 TO 8 9.0 Nm (80 in-lb) MAX
8 TO 11
9.0 Nm (80 in-lb)
11 Nm (100 in-lb) MAX
Mounting Feet (all) 1.7-3.3 Nm (30-35 in-lb)
Figure 1
Main Terminal Hardware Installation
Bolt
Lock Washer
Flat Washer
Lug
Lug
Terminal
Conductors
Thread
Engagement
Figure 2
Life Cycles vs. Power Switched
Figure 3
Recommended Conductor Sizes
4. Recommended Conductor Sizes for
Continuous Current Carry
Many sources exist for recommending the proper
conductor size for a given current carry. Many of these
sources are concerned primarily with wire insulation
safety issues. Cable bundling, conduit types, length of
runs, etc., are all important considerations. With regard
to a contactor placed in line with the conductors, it is
important to make sure that the wire size is sufficient
such that the contactor terminals themselves do not
overheat, leading to a failure of the device. In most cases,
the primary path for removal of heat from the contactor
terminals is the conductors themselves. Convection to
atmosphere and conduction via the base mountings play
a lesser role in this type of contactor due to the nature of the
construction. TE has performed basic characterization of
many of the styles of contactors discussed herein, and the
data is presented in Figure 3. The recommended maximum
power terminal temperature for all EV/LEV contactors is
150° C continuous and 175° C for 1 hour.
For applications requiring larger conductors than can
practically be installed with single 4/0 AWG cable and
lugs, adapter buss extensions can be obtained from TE.
5. Auxiliary Circuits
Auxiliary contacts are available on most models.
Configurations available are: SPST-NO, SPST-NC and
SPDT. Auxiliary contacts are rated at 125Vac/ 1A or
30Vdc/3A. Contacts with gold plating for low level loads
are also available. For circuit voltage below 10V/0.1A,
gold contacts are recommended.
The auxiliary contact actuating method will indicate the true
position of the main contacts. The auxiliary contact actua-
tion is directly coupled to the main contact moving bridge,
and will not indicate “open” unless both contact gaps of the
double-make, Form X contact are fully disconnected. Keep
in mind that the auxiliary contact is mainly a status indica-
tion, and should not be used to directly power other loads
such as a relay coil or high power lamp load.
6. Environmental Considerations
All KILOVAC contactors are characterized for operation
in thermal, vibration, moisture and fluid environments.
Consult the appropriate data sheet for limits concerning
shock, vibration, temperature range and altitude limits. In
some cases, there may be variations in limits with regard
to “specified operation” or “survival only”.
7. Custom Configurations
Most parts can be ordered with a variety of combinations
of main terminal and coil configurations, auxiliary con-
tacts, interface connectors, coil voltages, etc. If you have
a requirement for a particular configuration not shown on
the data sheet, consult the factory for information regarding
custom configurations.
8. Summary
This Application Note is meant to address some of the
more common questions regarding the use of EV/LEV
contactors. In all cases, please refer to the applicable
product data sheet for specific information. Also, Product
Application Engineers are available to answer questions
regarding these products by calling 800-253-4560
x2055, or 805-220-2055.
Figure 2
Life Cycles vs. Power Switched
Figure 3
Recommended Conductor Sizes
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
Application Notes for MAP/CAP Contactors
Introduction - Product Capabilities
And Typical Applications
TE KILOVAC MAP/CAP contactors are designed to be the
highest performance, smallest and lightest weight, sealed
High Voltage contactors in the industry. With current carrying
capability of up to 500A and power switching up to 200kW,
they are used in a variety of commercial aerospace and
military applications. Primarily designed to switch resistive
loads, they can be used in a variety of circuit applications
bearing in mind a few important considerations. This appli-
cation note focuses on a few of the more common circuit
configurations, and what to consider when selecting, install-
ing and using the contactors.
1. Installation
TE KILOVAC MAP/CAP contactors can be mounted in any
orientation, and due to the nature of their hermetic seal and
isolated enclosure, can be mounted in close proximity to
other equipment. However, care must be taken with regard
to the termination of the power cables to the main termi-
nals. It is important that the main power connection lugs are
mated directly to the terminal seats. Be sure that the hard-
ware stackup is in the proper order, and that washers and
other spacers are not placed between the lug and terminal
seat. Extraneous connection resistance can cause consid-
erable power dissipation and terminal heating at high
current carry. Refer to Figure 1 and Table I for the recom-
mended hardware stackup and torque.
Use the same guidelines and torque maximum values for
stud terminal contactors as well.
2. Coils, Drive Circuits and Coil Economizing
Since the power required to close the contacts is generally
much greater than the required holding power, many
contactors can be packaged with low-profile coils that
utilize either an electronic economizer (switchmode PWM,
electronic cut-throat), or mechanical cutthroat economizer.
The economizer lets-through the higher power required for
contact closure, then reduces the power for holding, greatly
reducing the coil power consumption and heating. These
circuits are packaged with the contactor, and in most
cases include coil suppression components as well. For
customers who wish to provide their own circuitry, TE can
provide suggestions for driving the coils of all versions of
contactors. Four types of actuators are typically used:
a. Single Coil requiring customer economizer circuit
b. Single Coil with supplied electronic economizer
c. Dual Coil with supplied mechanical “cut-throat”
economizer
d. Dual Coil with supplied electrical “cut-throat” economizer
The advantages of each type of coil circuit are shown in
Table II.
3. Load Types and Power Switching Recommendations
In general, all MAP/CAP contactors are designed
primarily for connection and interruption of resistive
loads and slightly inductive loads (L/R<1ms). High
currents (up to 2000A) can be interrupted in case of
circuit faults, and high continuous currents upwards of
500A can be maintained through closed contacts.
Some important pints to consider are:
a. Closing into current spikes due to uncharged filter capac-
itors. Capacitors should be pre-charged
whenever possible to avoid excessive contact erosion
and nuisance welds. Keep inrush current spikes
below 650A at all times. Care should also be taken
when considering other high-inrush loads such as
lamps or motors.
Figure 1
Main Terminal Hardware Installation
THREAD
ENGAGEMENT(turns)
TORQUE
Less than 5 Use longer fastener
5 TO 7 7.9 Nm (70 in-lb) MAX
7 TO 8 9.0 Nm (80 in-lb) MAX
8 TO 11
9.0 Nm (80 in-lb)
11 Nm (100 in-lb) MAX
Mounting Feet (all) 1.7-3.3 Nm (30-35 in-lb)
Bolt
Lock Washer
Flat Washer
Lug
Lug
Terminal
Conductors
Thread
Engagement
Table II
Coil Configurations
Type Advantage
Electronic PWM Operates over widest
voltage range
Electronic CT Simple, Robust, EMC
Compliant
Mechanical CT Simple, robust, fastest
operate time
Single Coil -
(customer economized)
Flexibility, lower initial cost
Figure 1
Main Terminal Hardware Installation
THREAD
ENGAGEMENT(turns)
TORQUE
Less than 5 Use longer fastener
5 TO 7 7.9 Nm (70 in-lb) MAX
7 TO 8 9.0 Nm (80 in-lb) MAX
8 TO 11
9.0 Nm (80 in-lb)
11 Nm (100 in-lb) MAX
Mounting Feet (all) 1.7-3.3 Nm (30-35 in-lb)
Bolt
Lock Washer
Flat Washer
Lug
Lug
Terminal
Conductors
Thread
Engagement
Table II
Coil Configurations
Type Advantage
Electronic PWM Operates over widest
voltage range
Electronic CT Simple, Robust, EMC
Compliant
Mechanical CT Simple, robust, fastest
operate time
Single Coil -
(customer economized)
Flexibility, lower initial cost
Figure 1
Main Terminal Hardware Installation
THREAD
ENGAGEMENT(turns)
TORQUE
Less than 5 Use longer fastener
5 TO 7 7.9 Nm (70 in-lb) MAX
7 TO 8 9.0 Nm (80 in-lb) MAX
8 TO 11
9.0 Nm (80 in-lb)
11 Nm (100 in-lb) MAX
Mounting Feet (all) 1.7-3.3 Nm (30-35 in-lb)
Bolt
Lock Washer
Flat Washer
Lug
Lug
Terminal
Conductors
Thread
Engagement
Table II
Coil Configurations
Type Advantage
Electronic PWM Operates over widest
voltage range
Electronic CT Simple, Robust, EMC
Compliant
Mechanical CT Simple, robust, fastest
operate time
Single Coil -
(customer economized)
Flexibility, lower initial cost
Figure 1
Main Terminal Hardware Installation
Table I
Table II
Coil Configurations
KILOVAC
High Voltage Relays
7
PAGE 109
KILOVAC High Voltage Relays
Application Notes for MAP/CAP Contactors (Continued)
b. Large current spikes through closed contacts. Large
current spikes through closed contacts in excess of
3000A can sometimes cause spot welding or contact
levitation. Consult with the factory if your application
requires passing large current pulses. Many contactors
can be ordered with “Dual Contact” arrangements (Arcing
contacts of harder material in parallel with high current
carry material).
c. Circuit inductance. Contactor break-arcs generally
last as long as it takes to dissipate the stored inductive
energy of the load (t (arc) = 1.1*L/R).
Longer arcs due to circuit inductance can accelerate
contact wear, and in extreme cases, can cause contactor
failure. TE recommends that the time constant of the load
be less than 1ms for safe operation and maximum life.
Contactor life is a function of the power level switched.
Higher make/break currents erode contact materials
faster and accelerate loss of dielectric withstanding
between the open contacts. Figure 2 can be used as a
guideline for estimating product life at a given load.
Longer arcs due to circuit inductance can accelerate
contact wear, and in extreme cases, can cause contactor
failure. TE recommends that the time constant of the load
be less than 1ms for safe operation and maximum life.
Contactor life is a function of the power level switched.
Higher make/break currents erode contact materials
faster and accelerate loss of dielectric withstanding
between the open contacts. Figure 2 can be used as a
guideline for estimating product life at a given load.
4. Recommended Conductor Sizes for Continuous Current Carry
Many sources exist for recommending the proper
conductor size for a given current carry. Many of these
sources are concerned primarily with wire insulation
safety issues. Cable bundling, conduit types, length of
runs, etc., are all important considerations. With regard
to a contactor placed in line with the conductors, it is
important to make sure that the wire size is sufficient
such that the contactor terminals themselves do not
overheat, leading to a failure of the device. In most cases,
the primary path for removal of heat from the contactor
terminals is the conductors themselves. Convection to
atmosphere and conduction via the base mountings play
a lesser role in this type of contactor due to the nature of the
construction. TE has performed basic characterization of
many of the styles of contactors discussed herein, and the
data is presented in Figure 3.
The recommended maximum power terminal
temperature for all MAP/CAP contactors is 150° C
continuous and 175° C for 1 hour.
For applications requiring larger conductors than can
practically be installed with single 4/0 AWG cable and
lugs, adapter buss extensions can be obtained from TE.
5. Auxiliary Circuits
Auxiliary contacts are available on most models.
Configurations available are: SPST-NO, SPST-NC and
SPDT. Auxiliary contacts are rated at 125Vac/ 1A or
30Vdc/3A. Contacts with gold plating for low level loads
are also available. For circuit voltage below 10V/0.1A,
gold contacts are recommended. The auxiliary contact actu-
ating method will indicate the true position of the main con-
tacts. The auxiliary contact actuation is directly coupled to
the main contact moving bridge, and will not indicate “open”
unless both contact gaps of the double-make, Form X con-
tact are fully disconnected. Keep in mind that the
auxiliary contact is mainly a status indication, and should
not be used to directly power other loads such as a relay
coil or high power lamp load.
Figure 2
Life Cycle vs. Power Switched
Figure 3
Recommended Conductor Sizes
Figure 1
Main Terminal Hardware Installation
THREAD
ENGAGEMENT(turns)
TORQUE
Less than 5 Use longer fastener
5 TO 7 7.9 Nm (70 in-lb) MAX
7 TO 8 9.0 Nm (80 in-lb) MAX
8 TO 11
9.0 Nm (80 in-lb)
11 Nm (100 in-lb) MAX
Mounting Feet (all) 1.7-3.3 Nm (30-35 in-lb)
Bolt
Lock Washer
Flat Washer
Lug
Lug
Terminal
Conductors
Thread
Engagement
Table II
Coil Configurations
Type Advantage
Electronic PWM Operates over widest
voltage range
Electronic CT Simple, Robust, EMC
Compliant
Mechanical CT Simple, robust, fastest
operate time
Single Coil -
(customer economized)
Flexibility, lower initial cost
Figure 1
Main Terminal Hardware Installation
THREAD
ENGAGEMENT(turns)
TORQUE
Less than 5 Use longer fastener
5 TO 7 7.9 Nm (70 in-lb) MAX
7 TO 8 9.0 Nm (80 in-lb) MAX
8 TO 11
9.0 Nm (80 in-lb)
11 Nm (100 in-lb) MAX
Mounting Feet (all) 1.7-3.3 Nm (30-35 in-lb)
Bolt
Lock Washer
Flat Washer
Lug
Lug
Terminal
Conductors
Thread
Engagement
Table II
Coil Configurations
Type Advantage
Electronic PWM Operates over widest
voltage range
Electronic CT Simple, Robust, EMC
Compliant
Mechanical CT Simple, robust, fastest
operate time
Single Coil -
(customer economized)
Flexibility, lower initial cost
KILOVAC High Voltage Relays
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
Application Notes for MAP/CAP Contactors (Continued)
Application Notes on Coil Power Economizing using PWM Circuits
6. Environmental Considerations
All TE KILOVAC contactors are characterized for opera-
tion in thermal, vibration, moisture and fluid environments.
Consult the appropriate data sheet for limits concerning
shock, vibration, temperature range and altitude limits. In
some cases, there may be variations in limits with regard to
“specified operation” or “survival only”.
7. Custom Configurations
Most parts can be ordered with a variety of combinations
of main terminal and coil configurations, auxiliary con-
tacts, interface connectors, coil voltages, etc. If you have
a requirement for a particular configuration not shown on
the data sheet, consult the factory for information regarding
custom configurations.
8. Summary
This Application Note is meant to address some of the
more common questions regarding the use of MAP/CAP
contactors. In all cases, please refer to the applicable
product data sheet for specific information.
Also, Product Application Engineers are available to
answer questions regarding these products by calling
800-253-4560 x2055, or 805-220-2055.
Introduction - Reducing Coil Power Dissipation through
the use of PWM Circuits
The coil power of most TE KILOVAC Relays and Contactors
can be reduced after Pickup by using several economizing
schemes. One of the most popular methods used in many
of our standard products, and one that is suitable for imple-
mentation by customers, is the Pulse Width Modulated
(PWM) coil driver.
1. Typical PWM Coil Drive Circuit
Figure 1 shows a typical PWM coil drive/economizer
circuit.
In the circuit shown, the “Fast Dropout” (FDO) and PWM
driver are energized simultaneously for a sufficient time
to allow the contacts to fully close. The PWM driver is
then modulated such that the stored coil energy is
utilized during the PWM driver “OFF” time to circulate
holding current through the FDO driver and freewheeling
diode. Since the holding current is much lower
than the current required for pickup, the holding power
for the contacts is greatly reduced.
The Fast Dropout circuit allows for the switching in/out of
the “free-wheeling” diode. When power is removed, the
FDO and PWM drivers will turn off, causing the stored
energy of the coil to be rapidly dissipated in the body
diodes. This minimizes the decay time of the coil current
and facilitates a fast opening of the relay contacts.
PWM
Fast Drop Out
RTN
Free-w heeling Diode
PWRCoil
Coil_RTN
Body Diode
Body Diode
Drive_PWM
Drive_FDO
Pickup PWM
Pulse
Fast Drop-out FET stays on during operation. FDO and
Power can be applied simultaneously
Filtering/Protection should be applied to FET gates as required.
For higher energy coils, additional TV S protection may be required
across FET drain-to-source.
Relay Coil
Coil Current Return During PWM "ON"
Coil Current Return During PWM "OFF"
Figure 1
Coil Drive Circuit
KILOVAC
High Voltage Relays
7
PAGE 111
KILOVAC High Voltage Relays
Application Notes on Coil Power Economizing using PWM Circuits (Continued)
This fast opening is useful for circuit interruption, and it
allows the over travel mechanism of the contact actuator to
work effectively in breaking minor contact welds that may
occur when closing the contacts.
Allowing the free-wheeling diode to remain across the
coil would significantly increase the contact opening
time and opening speed, and possibly result in nuisance
contact welds and/or reduced capability to interrupt
circuit currents.
If additional diodes are required to protect the FET body
diodes, select a Transient Voltage Suppressor (TVS) diode
with a breakdown rating lower than that of the driver FET
body diode. In general, a higher voltage TVS diode will
result in faster contact opening and higher clamping
voltage, while a lower voltage TVS diode will result in slower
contact opening and lower clamping voltage. For more
detailed information regarding TVS diode selection, contact
TE and request the report titled DC Relay Magnetic Energy
Determination and Transient Voltage suppressor Diode
Selection.
1.1 Recommended Operating Frequency and
Duty Cycle
The frequency at which the PWM circuit is operated should
be high enough such that the oscillation of the coil current
does not lead to audible noise being generated by the mag-
netic components and coil winding. For most KILOVAC
contactors, a coil drive frequency > 15 kHz is usually
sufficient to ensure that nuisance audible noise is not
generated. The PWM duty cycle required for economizing
power while maintaining sufficient holding force can be
calculated from the required holding current as
follows:
Duty Cycle(%) = (Ihold*R(T)Coil/Vsource)*100 (1)
Where:
R(T) = Coil Resistance at Temperature
Ihold = Required Holding Current
Vsource = Source Voltage
Contact TE regarding the minimum required hold current
needed for a particular Part Number. In general, divide the
specified dropout voltage by the coil resistance at 20°C, and
add 25% above that to get an estimate of the value to use in
equation (1) for Ihold.
2.0 Summary
This Application Note is meant to address some
of the more common questions regarding the use of
PWM circuits for coil power economization. In all cases,
please refer to the applicable product data sheet for
specific information.
TE can also recommend alternative solutions for mechanical
dual-coil economizers, as well as “Electronic Cut-Throat”
economizers. Product Application Engineers are available to
answer questions regarding this subject by calling
800-253-4560 x2055, or 805-220-2055.
Engineering Notes
KILOVAC High Voltage Relays and Contactors
AEROSPACE, DEFENSE & MARINE /// HIGH PERFORMANCE RELAYS
