EP HIGH VOLTAGE AND CURRENT CUT-OFF CAPACITY IN A COMPACT PACKAGE EP-RELAYS FEATURES 150A 2 Form A 150A 1 Form A 60A * Control of large voltages and currents The relays have a sealed construction that is filled with a hydrogen gas compound, and use a permanent magnet to establish a magnetic path for the arc. This allows them to switch high-level DC voltages of up to 400V DC. * Compact size and light weight The capsule contact construction is filled with a gas that has excellent thermal dissipation and insulation characteristics. Because of this we have been able to reduce the contact gap to one tenth that of conventional relays, and produce a compact and light design. * No arc space is required: size including arc space 1/9 (compared to conventional contactors) The arc is not exposed to the outside, therefore, no arc space is not required. * Safety construction The arc is not exposed, therefore, the contactor is explosion proof and intrinsically safe. * Quiet: operation noise 1/4 (compared to conventional contactors). Along with the above-mentioned miniaturization, the operation noise has been reduced to 70dB, and, in addition, the operation noise remains unchanged when a current of 1000A or more is interrupted. * High contact reliability The contact part is hermetically sealed, hence the contact resistance remains stable regardless of the ambient conditions. * Mounting direction is not specified The weight of the movable parts is light, and also the restoring force is large, hence the contactor is relatively unaffected by gravity. * Line-up of indicator types (150A Type only) 1 Form A and 1 Form B types with indicators for detecting welding of the main contacts are available. * 12 and 24V DC coil voltage types are available. * Screw terminal blocks for easy wiring. SPECIFICATIONS Contact Type Arrangement Nominal switching capacity (resistive load) Short term current Max. cut-off current Rating Overload opening/closing rating Reverse cut-off current Contact voltage drop (Max.) Nominal operating power Expected life Mechanical (min. Electrical operations) 150A type 1 Form A, 2 Form A 150A 400V DC 150A 277V AC 300A (10min)(harness wire: 40mm2) 2,500A 300V DC (3 cycles)#1 600A 400V DC (Min. 1,000 cycles) -200A 200V DC (Min. 500 cycles) 0.1V (When current [is 150A per 1] contact set) 35W (Inrush, approx 0.1s) 5W ( Stable ) 105 3 x 103 150A 400V DC (L/R & 1ms) Notes: Same specifications as the 12 V type. Condition: Nominal switching 100cycles, each cut off 2,500A #2 Conditions: Varistor used for coil surge absorption. Note: if a diode is used the life will be lower. #1 388 60A type 1 Form A 60A 400V DC 60A 277V AC 120A (15min)(harness wire: 15mm2) 600A 300V DC (5 cycles) 180A 400V DC (Min. 100 cycles) #2 -60A 200V DC (Min. 1,000 cycles) #2 0.1V (When current [is 60A per 1] contact set) Max. 5W 2 x 105 3 x 103 60A 400V DC (L/R & 1ms#2) EP Characteristics Min. 100 M (at 500 V DC)*1 AC 2,500 Vrms for 1 min.*2 AC 2,500 Vrms for 1 min.*2 Max. 50ms*3 Max. 30ms*4 Min. 196 m/s2 {20 G}*5 Min. 490 m/s2 {50 G}*6 43 m/s2 {4.4 G} 10 to 200Hz*7 43 m/s2 {4.4 G} 10 to 200 Hz*8 -40C to +80C*9 -40F to +176F Initial insulation resistance Between open contacts Initial breakdown voltage Between contact and coil Operate time (at 20C) (at nominal voltage) Reset time (without diode) (at 20C) (at nominal voltage) Functional Shock resistance Destructive Functional Vibration resistance Destructive Conditions for operation, Ambient temperature transport and storage (Not freezing and condensing at low Humidity temperature) 5 to 85% R.H. 150 A 1 Form A: 600 g 21.16oz 150 A 2 Form A: 1,100 g 38.80oz 60 A: 340 g 12.00oz Unit weight Remarks: *1 Measurement at same location as "Initial breakdown voltage" section. *2 Detection current: 10mA. *3 Nominal voltage applied to the coil, excluding bounce time. *4 Nominal voltage applied to the coil. *5 Half-wave pulse of sine wave: 11 ms; detection time: 10s. *6 Half-wave pulse of sine wave: 6 ms. *7 Detection time: 10 s. *8 3 directions, each 4 hours. *9 Storage: Max.85C 185F. Indicator ratings Arrangement Material Rating(resistive load) Contact resistance 1 Form A 1 Form B Gold-clad 0.1 A 30 V DC Max. 100 m Note: Indicator type is only available for the 150 A type. TYPICAL APPLICATIONS * UPS (uninterruptible power supplies) * Solar power generation systems * Unmanned transport carts * Battery inspection and testing equipment * Welding equipment ORDERING INFORMATION Ex. A EP 1 5 0 Product Name Contact arrangement Contact rating EP 1: 1 Form A 2: 2 Form A 5: 150A 6: 60A 12 Indicator contact arrangement 0: without indicator contact 1: a contact (150A type only) 3: b contact (150A type only) Coil voltage 12: 12V DC 24: 24V DC 389 EP TYPES AND COIL DATA (at 20C 68F) Pick-up voltage, V DC (max.) (at 20C) Coil voltage, V DC Part No. Drop-out voltage, V DC (min.) (at 20C) Nominal coil current, mA (10%) (at 20C) 1 V DC 2.8 A (at peak)* AEP25012* AEP15012* 12 V DC 9 V DC AEP16012 0.415 A 1.9 A (at peak)* 2.2 A (at peak)* 0.208 A AEP25024* 24 V DC AEP15024* 18 V DC 2 V DC AEP16024 Operating power, W (12 V DC, at 20C) Max. allowable voltage, V DC 35W(Inrush, approx. 0.1S) 5W(Stable) Max. 5W 35W(Inrush, approx. 0.1S) Max. 5W (1 Form A) Max. 6W (2 Form A) Max. 5W 16 V DC 32 V DC Note: *Same coil data as Indicator type. When using a DC power supply use one that has a leeway of at least 150% current capacity. Packing quantity Types 150A 2 Form A 150A 1 Form A 60A 1 Form A SPARE PARTS Inner 1pc. 1pc. 1pc. Outer 5pcs. 10pcs. 20pcs. Installing parts M8 nut with washer for 150A type M5 screw for 60A type M4 screw for 30A type Bus bar for 60A type Part No. Packing Quantity AEV801 2pcs. AEV802 AEV803 AEV804 2pcs. 2pcs. 1pc. mm inch DIMENSIONS 150A 2 Form A Schematic (TOP VIEW) 6: Coil (-) 5: Coil (+) 4- 5 0 .5 .1 4- .2 17 .004 3 - 4 + 1 + 3- 2 +4 7.7 .303 12 3 78 9 456 99 XYZ 2- 6 9.5 34.0 73.0 .374 1.339 2.874 7 5 90.0 78.0 3.543 3.071 .008 4+ 1+ Both input and load sides have polarities (+) and (-). 8 0.2 3- 29.0 1.142 1+ 6 .236 -2 3.5 27.0 1.063 .138 66.0 2.598 0.2 .008 76.0 2.992 96.0 3.780 5 .197 Coil input terminal (M3.5) 5 terminal: input (+) side 6 terminal: input (-) side Mounting dimensions M8 nut; AEV801 26.0 1.024 Plate (Part No., rating, schematic and Lot No.) General tolerance: less than 10 .394 0.3 .012 10 .394 to 50 1.969 0.6 .024 more than 50 1.969 1.0 .039 390 73.5 2.894 (terminal height) 87.1 3.429 20.0 .787 (terminal height) 76 2.992 78 3.071 4- 5.5 4- .217 26.0 1.024 13.0 .512 EP mm inch 150A 2 Form A (Indicator Type) Schematic (TOP VIEW) 1 Form A 4- 5 0 .5 .1 4- .2 17 .004 Indicator input terminal (M3.5) 7 terminal: NO or NC 8 terminal: COM 3 - 4 + 1 + 2 - 3- 6: Coil (-) 5: Coil (+) +4 12 3 78 9 456 99 Coil input terminal (M3.5) 5 terminal: input (+) side 6 terminal: input (-) side 6 XYZ 8 3- 34.0 73.0 1.339 2.874 7 7.7 .303 29.0 1.142 1+ 1 Form B -2 3.5 27.0 1.063 .138 66.0 2.598 76.0 0.2 2.992 .008 96.0 3.780 6 .236 4+ 1+ 2- 8: Indicator: COM 7: Indicator: NO Both input and load sides have polarities (+) and (-). 5 78.0 0.2 .008 90.0 3.071 3.543 9.5 .374 6: Coil (-) 5: Coil (+) 5 .197 M8 nut; AEV801 26.0 1.024 20.0 .787 (terminal height) 87.1 3.429 73.5 2.894 (terminal height) 20.0 .787 (terminal height) 3- 1+ 2- 8: Indicator: COM 7: Indicator: NC Both input and load sides have polarities (+) and (-). Mounting dimensions 76 2.992 26.0 1.024 13.0 .512 Plate (Part No., rating, schematic and Lot No.) 4+ 78 3.071 4- 5.5 4- .217 General tolerance: less than 10 .394 0.3 .012 10 .394 to 50 1.969 0.6 .024 more than 50 1.969 1.0 .039 150A 1 Form A Schematic (TOP VIEW) .1 0 0 .5 .0 5 17 2- .2 2- 6: Coil (-) 5: Coil (+) 7.7 .303 6 4 1 + 2 - 2- 12 3 Coil input terminal (M3.5) 5 terminal: input (+) side 6 terminal: input (-) side XYZ 1+ - 2 6 .236 3.5 .138 27.0 1.063 64.0 2.520 76.0 0.2 2.992 .008 94.0 3.701 Plate (Part No., rating, schematic and Lot No.) 76 2- 5.5 2.992 2- .217 20.0 .787 (terminal height) 87.1 3.429 21.0 .827 Mounting dimensions M8 nut; AEV801 73.5 2.894 (terminal height) 19.5 .768 78 9 456 99 7 44.0 0.2 1.732 .008 29.0 1.142 1+ Both input and load sides have polarities (+) and (-). 5 8 56.0 2.205 10.8 .425 9.5 .374 44 1.732 26.0 1.024 13.0 .512 General tolerance: less than 10 .394 0.3.012 10 .394 to 50 1.969 0.6 .024 more than 50 1.969 1.0 .039 391 EP 150A 1 Form A (Indicator Type) 0 .5 .0 5 7 2- .21 2- Indicator input terminal (M3.5) 7 terminal: NO or NC 8 terminal: COM mm inch Schematic (TOP VIEW) 1 Form A type .1 0 7.7 .303 4 6: Coil (-) 5: Coil (+) 6 2 - 5 12 3 78 9 456 99 7 1+ 1+ 2- 8: Indicator: COM 7: Indicator: NO Both input and load sides have polarities (+) and (-). Coil input terminal (M3.5) 5 terminal: input (+) side 6 terminal: input (-) side XYZ 44.0 0.2 1.732 .008 (9.5) 29.0 (.374) 1.142 19.5 .768 56.0 2.205 1 + 8 17.8 .701 10.8 .425 9.5 .374 6 .236 - 2 3.5 27.0 64.0 0.2 76.0 94.0 1 Form B type 6: Coil (-) 5: Coil (+) 21.0 .827 20.0 .787 (terminal height) 87.1 3.429 73.5 2.894 (terminal height) 15.0 .591 (terminal height) M8 nut; AEV801 Mounting dimensions 76 2- 5.5 2.992 2- .217 26.0 1.024 13.0 .512 Plate (Part No., rating, schematic and Lot No.) 1+ 2- 8: Indicator: COM 7: Indicator: NC Both input and load sides have polarities (+) and (-). 44 1.732 General tolerance: less than 10 .394 0.3 .012 10 .394 to 50 1.969 0.6 .024 more than 50 1.969 1.0 .039 60A Schematic (TOP VIEW) 6: Coil 5: Coil 04 2- 2.2 5.5 0 17 .1 .0 76.0 2.992 61.0 0.2 2.402 .008 49.0 1.929 45.0 1.772 (17.9) (.705) 2.5 .098 1+ Coil input terminal (M3.5) 6 38.0 30.2 26.00.2 13 1.496 1.189 1.024.008 .512 1 9.5 .374 6.55 .258 2 - 5 + 7.7 .303 M4 screw: AEV803 (built-in) 13.0 .512 Plate (Part No., rating, schematic and Lot No.) General tolerance: less than 10 .394 0.3 .012 10 .394 to 50 1.969 0.6 .024 more than 50 1.969 1.0 .039 392 79.9 3.146 63.9 2.516 Mounting dimension M5 screw: AEV802 20.0 .787 (terminal height) 62.0 2.441 (terminal height) Bus bar (15sq): AEV804 (built-in) 71.0 2.795 2- Load side has polarities (+) and (-). 26.0 1.024 61 2.402 26 1.024 2- 5.5 2- .217 EP REFERENCE DATA 1-(1) Ambient temperature characteristics (150 A type) 1-(2) Ambient temperature characteristics 2. Max. switching capacity Sample:AEP16012, 3pcs Sample: AEP15012, 3pcs 40 8 6 30 20 Ambient temperature C F 4 2 -20 -40 0 -4 -40 32 Ambient temperature, C F -2 40 74 20 68 -4 Pick up voltage 60 110 Drop out voltage -20 -4 -40 -40 80 146 x- 1000 xDrop out voltage x- 10 0 32 20 68 40 74 60 110 80 146 150A type DC, AC 400V resistive load Contact current, A Variation ratio, % Variation ratio, % 10 -10 xPick up voltage -6 100 60A type DC, AC 400V resistive load 10 -20 -30 -8 1 -40 -10 1 10 100 1000 Contact voltage, V 3. Switching life curve 4. Cut-off life curve 5. Carrying performance curve 105 1000 150A type DC, AC 400V resistive load 10 100 150A type DC400V resistive load Time (sec) 104 Life (cycle) Life (x103 cycle) 100 150A type (Electric cable 40mm2) 1000 10 100 60A type DC, AC 400V resistive load 60A type DC400V resistive load 1 10 100 1000 Contact current, A 1 100 1000 60A type (Electric cable 15mm2) 10 10000 Cut-off current, A 10 100 1000 Carrying current, A NOTES 1. When installing the relay, always use washers to prevent loosening of the screws. Tighten each of the screws within the rated ranges given below. Exceeding the maximum torque may result in breakage. Mounting is possible in either direction. * M8 screw (150 A main terminal): 8 to 10 N*m * M5 screw (150 A, 60 A main unit mounting section): 2.5N*m to 3.6N*m * M4 screw (60 A main terminal): 1.8 to 2.7 N*m * M3.5 screw (Input terminal): 0.84 to 1.2 N*m 2. The coils (150 A type) and contacts (60 A, 150 A) of the relay are polarized, so follow the instructions in the connection schematic when connecting the coils and contacts. Type 150 A has contains a reverse surge voltage absorption circuit; therefore a surge protector is not needed. We recommend installing a surge protector varistor (ZNR) for the 60 A types. Avoid using a diode as this may result in decreased cut-off capability. 3. As a general rule, do not use a relay if it has been dropped. 4. Avoid mounting the relay in strong magnetic fields (near a transformer or magnet) or close to an object that radiates heat. 5. Electrical life This relay is a high-voltage direct-current switch. In its final breakdown mode, it may lose the ability to provide the proper cutoff. Therefore, do not exceed the indicated switching capacity and life. (Please treat the relay as a product with limited life and replace it when necessary.) In the event that the relay loses cut-off ability, there is a possibility that burning may spread to surrounding parts, so configure the layout so that the power is turned off within one second. 6. Permeation life of internal gas This relay uses a hermetically encased contact (capsule contact) with gas inside. The gas has a permeation life that is affected by the temperature inside the capsule contact (ambient temperature + temperature rise due to flow of electrical current). For this reason, make sure the ambient operating temperature is between -40 and 80C -40 and +176F, and the ambient storage temperature is between -40 and 85C -40 and +185F. 7. The case is designed so that it will not come off with normal handling. If you remove the case, the relay will not function as intended, and its performance cannot be guaranteed. 393 EP 8. If the power is turned off and then immediately on after applying the rated voltage (current) continuously to the relay's coil and contact, the resistance of the coil will increase due to a rise in the coil temperature. This causes the pick-up voltage to rise, and possibly exceed the rated pick-up voltage. In these circumstances, take measures such as reducing the load current, limiting the duration of current flow, and applying a coil voltage higher than the rated operating voltage (quick start). 9. The coil must only be supplied with its rated voltage. The voltage waveform supplied to the coil should be rectangular. 10. Take steps to ensure that voltages that exceed the maximum allowed voltage for a coil are never continuously applied. 11. Take steps to ensure that the rated voltage and current values for the contacts are never exceeded. 12. The rated control capacity and life are given as guides. The contact life is heavily influenced by the type of load and other related conditions, and these factors must be given due consideration when using the relay. 13. Main contact ratings in the ratings apply to when there is a resistive load. 394 9/1/2000 14. If you are using an inductive load (L load) such that L/R > 1 ms, add surge protection in parallel with the inductive load. If this is not done, the electrical life will decrease and cut-off failure may occur. 15. When using the 150 A type, mount it as far away as possible from amateur wireless transmitters or devices that may generate large surges. To prevent malfunctioning due to high emission levels, it may be neccessary to take measures for E.M.I., such as adding a line noise filter or an electromagnetic shield. 16. Since coil current control is performed, a slight amount of superimposed line noise may be generated in the input line system. If this noise must be removed, install a line noise filter. 17. Be careful that foreign matter and oils do not stick to the main terminal part. It is likely to cause a terminal part to give off unusual heat. Use the following specifications for the harness bus bar that the relay connects to: * 150A type: nominal cross sectional area: min. 38mm2. * 60A type: nominal cross sectional area: min. 14mm2. 18. Avoid excessive load applied to the terminal in case of installing such as a bus bar etc., because it might give bad influence to the opening and closing performance. * M8 screw terminal (150A main terminal part) Terminal pulling up strength ; Max.100N per terminal The up-down rotation torque applied to the terminal ; Max.15N*m 19. For AC cut-off there is no contact polarity, but confirm the electrical life using the actual load. In the case of DC cut-off the contacts have polarity, so take due care. All Rights Reserved, (c) Copyright Matsushita Electric Works, Ltd. Go To Online Catalog