EV (AEV) Capsule contact Mechanism and High-capacity Cut-off Compact Relay 10A 20A 80A 120A EV RELAYS (AEV) FEATURES TYPICAL APPLICATIONS * Compact and lightweight Charged with hydrogen gas for high arc cooling capacity, short gap cutoff has been achieved at high DC voltages. * Safety High safety achieved with construction that prevents explosions by keeping the arc from leaking. * High contact reliability Since the contact portion is sealed in hydrogen gas, there is no contact oxidation. It is also dustproof and waterproof. High DC voltage applications such as * Electric vehicle * Hybrid vehicle * Fuel-cell vehicle * Battery charge and discharge systems * Construction equipment 300A RoHS compliant ORDERING INFORMATION AEV 0 Contact arrangement 1: 1 Form A (Screw terminal, TM, with terminal protection cover) 5: 1 Form A (TM type) Contact rating 1: 10 A 2: 20 A 8: 80 A 9: 300 A 4: 120 A Coil voltage 12: 12V DC 24: 24V DC Coil terminal structure Nil: Plug-in (Faston) (for 20 A type), Connector (for 80 A, 120 A and 300 A) 2: Plug-in (Faston) (for 10 A type with terminal protection cover) Panasonic Corporation Automation Controls Business Unit industrial.panasonic.com/ac/e ASCTB233E 201201-T EV (AEV) TYPES Type 10 A 20 A 80 A 120 A 300 A 10 A 80 A 120 A 300 A Nominal coil voltage Contact arrangement 12 V DC 1 Form A 24 V DC 1 Form A Part number AEV110122 AEV52012 AEV18012 AEV14012 AEV19012 AEV110242 AEV18024 AEV14024 AEV19024 Standard packing; Carton: 25pcs. Case: 100pcs (for 10 A type) Carton: 25pcs. Case: 50pcs (for 20 A type) Carton: 1pc. Case: 20pcs (for 80 A type) Carton: 1pc. Case: 20pcs (for 120 A type) Carton: 1pc. Case: 5pcs (for 300 A type) RATING 1. Coil data Type 10 A 20 A 80 A 120 A Nominal coil voltage 12 V DC Pick-up voltage (at 20C 68F) Max. 9 V DC Max. 9 V DC Max. 9 V DC Max. 9 V DC Drop-out voltage (at 20C 68F) Min. 1 V DC Min. 0.5 V DC Min. 1 V DC Min. 1 V DC Nominal operating current [10%] (at 20C 68F) 0.103 A 0.327 A 0.353 A 0.353 A 300 A Max. 9 V DC Min. 2 V DC 3.2 A (Inrush) 10 A 80 A 120 A Max. 18 V DC Max. 18 V DC Max. 18 V DC Min. 2 V DC Min. 2 V DC Min. 2 V DC 0.052 A 0.176 A 0.176 A Max. 18 V DC Min. 4 V DC 1.85 A (Inrush) 24 V DC 300 A ASCTB233E 201201-T Panasonic Corporation Automation Controls Business Unit Nominal operating power (at 20C 68F) 1.24 W 3.9 W 4.2 W 4.2 W 37.9 W (Inrush, approx. 0.1 sec.) 3.6 W (Stable) 1.24 W 4.2 W 4.2 W 44.4 W (Inrush, approx. 0.1 sec.) 3.8 W (Stable) Max. allowable voltage 16 V DC 32 V DC industrial.panasonic.com/ac/e EV (AEV) 2. Specifications 10A type 20A type Specifications 80A type 1 Form A 120 A type 300 A type 10A 400V DC 20A 400V DC 80A 400V DC 120A 400V DC (Carry current) 300A 400V DC 15A 2min, 30A 30sec (2mm2) 40A 10min, 60A 1min (3mm2) 120A 15min, 180A 2min (15mm2) 225A 3min, 400A 30sec. (38mm2) 400A 10 min, 600A 1 min. (100mm2) 1A 12V DC 1A 12V DC 1A 12V DC 1A 12V DC 1A 24V DC -- -- 800A 300V DC (Min. 1 cycles)*2 2,500A 300V DC (Min. 3 cycles)*3 Overload opening/closing rating*5 30A 400V DC (Min. 50 cycles)*2 60A 400V DC (Min. 50 cycles)*2 120A 400V DC (Min. 50 cycles)*2 600A 400V DC (Min. 300 cycles) Reverse direction cut-off*5 -- -- -120A 200V DC (Min. 50 cycle)*2 1,200A 300V DC (Min. 1 cycle)*2 800A 300V DC (Min. 5 cycles)*2 120A 400V DC (Min. 50 cycles)*2 -120A 200V DC (Min. 50 cycle)*2 Max. 0.5V (By voltage drop 6 V DC 10A) Max. 0.2V (By voltage drop 6 V DC 20A) Max. 0.067 V (By voltage drop 6 V DC 20A) Max. 0.03V (By voltage drop 6 V DC 20A) Max. 0.06V (300 A Carry current) Characteristics Item Contact arrangement Nominal switching capacity (resistive load) Short term current Min. switching capacity (resistive load)*1 Contact rating Max. cut-off current*5 Contact voltage drop (Initial) Insulation resistance (Initial) Breakdown voltage (Initial) Electrical characteristics Min. 100M (at 500 V DC, Measurement at same location as "Initial breakdown voltage" section.) Between open contacts Between contact and coil 2,500Vrms/min. (Detection current: 10mA) 2,500Vrms/min. (Detection current: 10mA) Operate time (at 20C 68F) Max. 50ms (Nominal coil voltage applied to the coil, excluding contact bounce time.) Max. 30ms (Nominal coil voltage applied to the coil, excluding contact bounce time.) Release time (at 20C 68F) Max. 30ms (Nominal coil voltage applied to the coil, without diode.) Max. 10ms (Nominal coil voltage applied to the coil, without diode.) Shock resistance Functional Min. 196m/s2 {20 G} (Half-wave pulse of sine wave: 11ms; detection time: 10s) Mechanical characteristics For ON: Min. 196m/s2 {20 G} (Half-wave pulse of sine wave: 11ms; detection time: 10s) For OFF: Min. 98m/s2 {10 G} (Half-wave pulse of sine wave: 11ms; detection time: 10s) Min. 490 m/s2 {50 G} (Half-wave pulse of sine wave: 6ms) Destructive Functional 10 to 200 Hz, Min.43 m/s2 {4.4 G} (Detection time: 10s) Destructive 10 to 200 Hz, Min.43 m/s2 {4.4 G} (Time of vibration for each direction; X, Y, Z direction: 4 hours) Vibration resistance Mechanical Expected life Conditions -300A 200V DC (Min. 100 cycles) Electrical (resistive load) Conditions for operation, transport and storage Mass (Approx.) Min. 105 10A 400V DC Min. 75,000*2 20A 400V DC Min. 3,000*2 Min. 2x105 80A 400V DC 30A 400V DC Min. 1,000*2 Min. 3,000*2 Ambient temperature: -40 to +80C -40 to +176F (Storage: Max. 85C 185F), Humidity: 5 to 85% R.H. (Not freezing and condensing at low temperature) 90 g 3.17 oz 180 g 6.35 oz 400 g 14.11 oz 400 g 14.11 oz 10 to 200 Hz, Min.44 m/s2 {4.5 G} (Detection time: 10s) 10 to 200 Hz, Min.44 m/s2 {4.5 G} (Time of vibration for each direction; X, Y, Z direction: 4 hours) 300A 400V DC Min. 1,000 Ambient temperature: -40 to +85C -40 to +185F (Storage: Max.85C 185F), Humidity: 5 to 85% R.H. (Not freezing and condensing at low temperature) 750 g 26.46 oz Notes: *1. This value can change due to the switching frequency, environmental conditions, and desired reliability level, therefore it is recommended to check this with the actual load. *2. The electrical load performance value for the 10A, 20A, 80A and 120 A types applies when a varistor is connected in parallel to the coil. Please be warned that working life will be reduced when a diode is used. *3. Condition: Nominal switching 10 cycles, each cut-off 2,500 A *4. The coil voltage 12 V DC type and 24 V DC type have the same specifications. *5. at L/R 1ms Panasonic Corporation Automation Controls Business Unit industrial.panasonic.com/ac/e ASCTB233E 201201-T EV (AEV) REFERENCE DATA 1.-(1) Ambient temperature characteristics (10 A type) 1.-(2) Ambient temperature characteristics (20 A type) 1.-(3) Ambient temperature characteristics (80 A type) Sample: EV relay 10 A, 3 pcs. Sample: EV relay 20 A, 3 pcs. Sample: EV relay 80 A, 3 pcs. X X 20 Ambient 10 temperature, C -20 0 -40 20 Drop-out voltage 30 Pick-Up voltage 20 20 40 60 -10 -10 Pick-Up -20 voltage -30 -20 -30 Pick-Up -20 voltage -30 -40 -40 -40 Sample: EV relay 300 A, 3 pcs. Drop-out voltage 30 Pick-Up 20 voltage Ambient 10 temperature, C -20 0 -40 40 60 80 -20 -40 0 20 -10 -20 -20 -30 -30 -40 -40 3. Switching life curve 40 60 80 80 A type, 400 V DC resistive load 100 120 A type, 400 V DC resistive load 10 20 A type, 400 V DC resistive load 10 A type, 400 V DC resistive load 1 1 4. Cut-off life curve 100000 10 80 A type 120 A type, 400 V DC resistive load 100 300 A type, 400 V DC resistive load (for Min. 900 A, 300 V DC) 120 A type 300 A type 104 Time, sec Life, cycle Life, cycle 300 A type, 400 V DC resistive load 1000 105 1000 20 A type, 400 V DC resistive load 100 Contact voltage, V 5. Carrying performance curve (80C 176F) *For 300 A, at 85C 185F 80 A type, 400 V DC resistive load 10000 80 300 A type, 400 V DC resistive load Pick-Up Drop-out voltage 20 voltage 30 Ambient 10 temperature, C 20 60 1000 40 -10 40 2. Max. value for switching capacity Contact current, A Variation ratio, % Variation ratio, % Sample: EV relay 120 A, 3 pcs. 40 Drop-out voltage 20 80 -10 1.-(5) Ambient temperature characteristics (300 A type) 10 A type 1000 120 A type, 400 V DC resistive load 100 10 10 A type, 400 V DC resistive load 10 1 30 Ambient 10 temperature, C -20 0 -40 1.-(4) Ambient temperature characteristics (120 A type) 1000 40 20 Ambient 10 temperature, C -20 0 -40 Drop-out voltage 60 80 40 40 Variation ratio, % 30 Variation ratio, % Variation ratio, % 40 1 10 ASCTB233E 201201-T 100 Contact current, A 100 80 A type, 400 V DC resistive load (for Min. 600 A, 300 V DC) 1000 1 100 Panasonic Corporation 20 A type 10 1000 Cut-off current, A 10000 Automation Controls Business Unit 1 10 100 1000 Carrying current, A industrial.panasonic.com/ac/e EV (AEV) DIMENSIONS (mm inch) The CAD data of the products with a CAD Data mark can be downloaded from: http://industrial.panasonic.com/ac/e 1. 10 A type External dimensions CAD Data 1-Load input terminal (+) #187 tab, 0.5t Schematic (TOP VIEW) 5-Coil terminal (No polarity) #187 tab, 0.5t 5:Coil 1 (+) 66.8 2.630 55.90.3 2.201.012 45 1.772 19.6 .772 8.6 .339 6:Coil Load side has polarities (+) and (-) 5 1 11.30.3 .445.012 2 (-) Mounting dimensions 6 2 4.50.2 dia. .177.008 dia. Mounting hole: 2-4.20.1 dia. 2-.165.004 dia. 14.10.3 .555.012 2-Load input terminal (-) #187 tab, 0.5t 6-Coil terminal (No polarity) #187 tab, 0.5t 0.4 .016 31.7 1.248 55.90.1 2.201.004 49.7 Max. 45 45.5 1.957 1.772 1.791 19.5 .768 General tolerance; less than 10 .394: 0.3 .012 10 to 50 .394 to 1.969: 0.6 .024 more than 50 1.969: 1.0 .039 31.6 1.244 37.9 1.492 5.7 .224 2. 20 A type External dimensions CAD Data 78.0 3.071 64.0 2.520 1-Load input terminal (+) #250 tab, 0.8t 22.5 .886 2-Load input terminal (-) #250 tab, 0.8t 19.0 40.0 .748 1.575 9.2 .362 22.8 .898 50.0 1.969 Schematic (TOP VIEW) Coil terminal (No polarity) #250 tab, 0.8t 2-6 dia. 2-.236 dia. 1 (+) Coil 2 (-) Coil Load side has polarities (+) and (-) Mounting dimensions 11.1 .437 5.8 .228 Mounting hole: 2-6.00.2 dia. 2-.236.008 dia. 37.01.0 1.457.039 64.00.1 2.520.004 General tolerance; less than 10 .394: 0.3 .012 10 to 50 .394 to 1.969: 0.6 .024 more than 50 1.969: 1.0 .039 Panasonic Corporation Automation Controls Business Unit industrial.panasonic.com/ac/e ASCTB233E 201201-T EV (AEV) 3. 80 A type External dimensions CAD Data 15.9 .626 (Bus bar width) - 1 (+) 8.0 dia. .315 dia. (Flat washer) (17.9) (.705) 7 .276 Schematic (TOP VIEW) 2 (-) 57.9 2.280 (Both ends of bus bar) 44.9 1.768 (M5 bolt pitch) 7.3 .287 Coil + 26.0 1.024 Coil 2 .079 2-Load input bus bar (-) 2-6.0 dia. 2-.236 dia. Connector part number: 7282-1020 (Yazaki) (Supplement) Harness side female connector part number: 7283-1020 (*Note) M5 bolt (M4) Mounting dimensions 1-Load input bus bar (+) 7.3 .287 63.5 2.500 Mounting hole: 2-6.00.2 dia. 2-.236.008 dia. 26.00.2 1.024.008 10 .394 63.50.2 2.500.008 75.0 79.0 2.953 3.110 24 .945 69.0 2.717 12 .472 45 1.772 (Connector position) Collar height: 5.7 .224 General tolerance; less than 10 .394: 0.3 .012 10 to 50 .394 to 1.969: 0.6 .024 more than 50 1.969: 1.0 .039 40.0 1.575 75.5 2.972 *Note: Separate connection of the terminal and lead wire is required. 4. 120 A type External dimensions CAD Data 16.0 .630 (Bus bar width) 7 .276 61.9 2.437 (Both ends of bus bar) 44.9 1.768 (M6 bolt pitch) (17.9) (.705) Schematic (TOP VIEW) 2 (-) 1 (+) 8.0 dia. (Flat washer) .315 dia. 7.3 .287 26.0 2 1.024 .079 Coil Coil Load side has polarities (+) and (-) 2-Load input bus bar (-) 2-6.0 dia. 2-.236 dia. 7.3 .287 63.5 2.500 (M4) 1-Load input bus bar (+) Connector part number: 7282-1020 (Yazaki) (Supplement) Harness side female connector part number: 7283-1020 (*Note) M6 bolt 10.00.6 .394.024 Mounting hole: 2-6.00.2 dia. 2-.236.008 dia. 26.00.2 1.024.008 75.0 80.0 2.953 3.150 24 .945 70.0 2.756 12 .472 Collar height: 5.7 .224 Mounting dimensions 45 1.772 (Connector position) 75.5 2.972 40.0 1.575 63.50.2 2.500.008 General tolerance; less than 10 .394: 0.3 .012 10 to 50 .394 to 1.969: 0.6 .024 more than 50 1.969: 1.0 .039 *Note: Separate connection of the terminal and lead wire is required. ASCTB233E 201201-T Panasonic Corporation Automation Controls Business Unit industrial.panasonic.com/ac/e EV (AEV) 5. 300 A type External dimensions CAD Data Schematic (TOP VIEW) 111 4.370 92 3.622 86 3.386 790.3 3.110.012 44 1.732 27 1.063 1-Load input bus bar (+) 1+ 1 (+) 2 (-) 2-Load input bus bar (-) 2- 6:Coil (GND) 5:Coil (V+) 63 60 470.3 27 2.480 2.362 1.850.012 1.063 5 6 Load side has polarities (+) and (-) 3-60.3 dia. 3-.236.012 dia. 6-Coil terminal (GND) 5 - Coil terminal (V+) Connector part number: 7282-1020 (Yazaki) (Supplement) Harness side female connector part number: 7283-1020 (*Note) Mounting dimensions Mounting hole: 3-6.00.2 dia. 3-.236.008 dia. 47.00.2 1.850.008 M8 bolt M8 Flange nut 24.5 .965 (13) (.512) 3 .118 39.3 1.547 5.7 .224 73.4 74.7 61.7 2.890 2.941 2.429 79.00.2 3.110.008 General tolerance; less than 10 .394: 10 to 50 .394 to 1.969: more than 50 1.969: more than 100 3.937: 0.3 .012 0.6 .024 1.0 .039 1.6 .063 *Note: Separate connection of the terminal and lead wire is required. Panasonic Corporation Automation Controls Business Unit industrial.panasonic.com/ac/e ASCTB233E 201201-T EV (AEV) NOTES 1. For general cautions for use, please refer to the"CAUTIONS FOR USE OF AUTOMOTIVE RELAYS". 2. When installing the relay, always use washers to prevent the screws from loosening. Tighten each screw within the rated range given below. Exceeding the maximum torque may result in breakage. Mounting is possible in either direction. * M4 screw (for 10A type): 1.8 to 2.7 N*m * M5 screw (for 20A, 80A, 120A and 300A types): 3 to 4 N*m
* M5 nut (for 80A type): 3 to 4 N*m * M6 nut (for 120A type): 6 to 8 N*m * M8 nut (for 300A type): 10 to 12 N*m 3. The coils (300 A type) and contacts (all type) of the relay are polarized, so follow the connection schematic when connecting the coils and contacts. Type 300 A contains a reverse surge voltage absorption circuit; therefore a surge protector is not needed. We recommend installing a surge protector varistor (ZNR) for the 10A, 20A, 80A and 120A types. Amount of proof energy: Min. 1 J Varistor voltage: 1.5 to 2.0 times of nominal voltage Avoid using a diode as this may result in decreased cut-off capability. 4. As a general rule, do not use a relay if it has been dropped. 5. Avoid mounting the relay in strong magnetic fields (near a transformer or magnet) or close to an object that radiates heat. 6. Electrical life This relay is a high-voltage direct-current switch. In its final breakdown mode, it may lose the ability to provide the proper cut-off. Therefore, do not exceed the indicated switching capacity and life. (Please treat the relay as a product with limited life and replace it when necessary.) In the event that the relay loses cut-off ability, there is a possibility that burning may spread to surrounding parts, so configure the layout so that the power is turned off within one second. 7. 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 (300A type is Max. 85C 185F), and the ambient storage temperature is between -40 and 85C -40 and +185F. 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. 9. Main contact ratings in the ratings apply to when there is a resistive load. 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. 12. As a guide, the insertion strength of the plug-in terminal into the relay tab terminal should be 40 to 70N (10A type), 40 to 80N (20A type). Please select a plug-in terminal (flat connection terminal) which comply with JIS C2809-1992. 10A type: for plate thickness 0.5mm and #187 tab terminal 20A type: for plate thickness 0.8mm and #250 tab terminal 13. Avoid excessive load applied to the terminal in case of installing such as a bus bar etc., Because it might adversely affect the opening and closing performance. 14. Use the specified connector for the connector terminal connection (80A, 120A and 300A) Yazaki Corporation 7283 - 1020 or equivalent 15. After the ON signal enters the 300A type, automatic coil current switching occurs after approximately 0.1 seconds. Do not repeatedly turn it OFF within that 0.1 seconds interval, as doing so may damage the relay. 10. For the 300 A type, drive the coil with a quick startup. (Built-in one-shot pulse generator circuit) 11. Be careful that foreign matter and oils and fats kind don't stick to the main terminal parts because it is likely to cause terminal parts to give off unusual heat. Also, please use the following materials for connected harnesses and bus bars. 10A type: Min. 2 mm2 nominal crosssectional area 20A type: Min. 3 mm2 nominal crosssectional area 80A type: Min. 15 mm2 nominal crosssectional area 120A type: Min. 38 mm2 nominal crosssectional area 300A type: Min. 100 mm2 nominal crosssectional area For Cautions for Use. ASCTB233E 201201-T Panasonic Corporation Automation Controls Business Unit industrial.panasonic.com/ac/e