Tyco Electronics KILOVAC EV200 Series User manual

7–21
Catalog 5-1773450-5 Dimensions are in inches and Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-2103-6000
Revised 9-08 millimeters unless otherwise reference purposes only. Canada: 1-905-470-4425 Hong Kong: 852-2735-1628
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Japan: 81-44-844-8013
www.tycoelectronics.com are metric equivalents. to change. C. America: 52-55-1106-0803 UK: 44-8706-080-208
KILOVAC High Voltage DC Contactors
KILOVAC High Voltage DC Contactors
7
KILOVAC EV200 Series Contactor With 1 Form X (SPST-NO)
Contacts Rated 500+ Amps, 12-900 Vdc
EV200 Series Contactor
(CZONKA Relay, Type III)
Product Facts
IDesigned to be the
smallest, lightest weight,
lowest cost sealed contactor
in the industry with its
current rating (500+A carry,
2000A interrupt at 320VDC)
IBuilt-in coil economizer —
only 1.7W hold power @
12VDC and it limits back
EMF to 0V. Models requiring
external economizer also
available
IOptional auxiliary contact
for easy monitoring of
power contact position
IHermetically sealed —
intrinsically safe, operates
in explosive/harsh
environments with no
oxidation or contamination
of coil or contacts, during
long periods of non-
operation
IVersatile coil/power
connections
IUL Recognized
for the U.S. and
Canada (File E208033)
All contact ratings & coil
versions may not be UL
Recognized
ICE marked for
EC applications
IAIAG QS9000 designed,
built and approved
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:
1Main power contacts
250 at end of life
3Does 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 䊳EV200AAANA
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.

7–22
Catalog 5-1773450-5 Dimensions are in inches and Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-2103-6000
Revised 9-08 millimeters unless otherwise reference purposes only. Canada: 1-905-470-4425 Hong Kong: 852-2735-1628
specified. Values in brackets Specifications subject Mexico: 01-800-733-8926 Japan: 81-44-844-8013
www.tycoelectronics.com are metric equivalents. to change. C. America: 52-55-1106-0803 UK: 44-8706-080-208
KILOVAC High Voltage DC Contactors
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 300 milliH maximum inductance
2) Estimates based on extrapolated data. User is encouraged to verify rating in actual application.
3) End of life when dielectric strength between terminals falls below 50 megohms @ 500VDC.
4) The maximum contact make and break power is estimated at 208KW.
Break only above 208KW to avoid contact welding.
100,000
10,000
1,000
100
10
11,000 10,000
100101
Continuous Current Carry Region Non-continuous Current Carry Region
200A
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

7–23
Cata og 5-1773450-5 Dimensions are in inches and Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-2103-6000
Revised 9-08 mi imeters un ess otherwise reference purposes on y. Canada: 1-905-470-4425 Hong Kong: 852-2735-1628
specified. Va ues in brackets Specifications subject Mexico: 01-800-733-8926 Japan: 81-44-844-8013
www.tycoe ectronics.com are metric equiva ents. to change. C. America: 52-55-1106-0803 UK: 44-8706-080-208
KILOVAC High Vo tage DC Contactors
KILOVAC High Voltage DC Contactors
7
For factory-direct application assistance,
dial 00-253-4560, ext. 2055, or
05-220-2055.
KILOVAC EV200B Series Contactor With 1 Form Y (SPST-NC)
Contacts Rated 500+ Amps, 12-900 Vdc
Product Facts
INormally closed version of
popular EV200 series
contactors
IDesigned to be the
smallest, lowest cost,
lightest weight sealed
contactor in the industry at
its current rating
IOptional auxiliary contacts
for monitoring position of
power contacts
IHermetically sealed —
operates in explosive/harsh
environments with no
oxidation or contamination
of coil or contacts during
long periods of non-
operation
INot position sensitive, can
be mounted in any
orientation
Ordering Information
Typical art Number 䊳EV200 BAANA
Series:
EV200 = 500+ Amp, 12-900VDC Contactor
Contact Form:
B = Normally Clos d
D = Normally Clos d, 1 SPDT Aux.
Coil Voltage (with Economizer):
A = 12/24 Vdc
Coil Terminals:
A = 15.3 in. (300 mm)
Coil Terminal Connector:
N = Non
Mounting & ower Terminations:
A = Bottom Mount & Mal 10 Max. M8
Thr ad d T rminals
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 + 5°C
Electrical Data
Voltage Rating —
Main Contacts (Max) — 750 Vdc
Current Rating, Continuous —
Main Contacts 1— 500A
Contact Resistance —
Main Contacts 2—
0.2 mΩmax above 300A
0.3 mΩmax between 50 and 300A
Hot Switching Performance
(Positive Polarity) 3—
200A make/ break @ 270Vdc —
10,000 cycles
600A make/ break @ 360Vdc —
100 cycles
00A break only @ 360Vdc —
15 cycles
1500A break only @ 360Vdc — 1 cycle
Mechanical Life (Min) —
100,000 cycles
Dielectric Withstand Voltage —
Terminal to Terminal/ Terminals to Coil —
1mA max @ 2,200 Vrms
Insulation Resistance —
Terminal to Terminal/ Terminals to Coil —
100MΩmin @ 500Vdc new
50MΩmin @ 500Vdc end of life
Coil Data 4
Nominal Coil Voltage 5—
Low range — 9.6-14 Vdc
High range — 19-2 Vdc
Pick Up (Max) @ 25°C —
9.6/1 .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 —
1 kHz
Hold Current —
0.9A/12 Vdc
0.3A/24 Vdc
Notes:
1Ambient conditions and conductor
design affect rating. Terminal tem-
perature rise should be 75° max
above ambient. Keep relay termi-
nals below 150° max continuous,
175° max for two hours, and
200° for 1 minute.
2Stabilized reading. ontact resist-
ance may exceed spec in the first
10 minutes of current carry.
3Units are polarity sensitive.
Approximately 50% de-rating
for reverse polarity switching.
onsult factory for review of
specific requirements.
4Over temperature range unless
noted.
5Voltage ranged sensed by contac-
tor 10 ms after application of
source voltage.
6Pickup duration 100 ms.

7–24
Cata og 5-1773450-5 Dimensions are in inches and Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-2103-6000
Revised 9-08 mi imeters un ess otherwise reference purposes on y. Canada: 1-905-470-4425 Hong Kong: 852-2735-1628
specified. Va ues in brackets Specifications subject Mexico: 01-800-733-8926 Japan: 81-44-844-8013
www.tycoe ectronics.com are metric equiva ents. to change. C. America: 52-55-1106-0803 UK: 44-8706-080-208
KILOVAC High Vo tage DC Contactors
For factory-direct application assistance,
dial 00-253-4560, ext. 2055, or
05-220-2055.
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)
2.58 ±.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)

7–25
Cata og 5-1773450-5 Dimensions are in inches and Dimensions are shown for USA: 1-800-522-6752 South America: 55-11-2103-6000
Revised 9-08 mi imeters un ess otherwise reference purposes on y. Canada: 1-905-470-4425 Hong Kong: 852-2735-1628
specified. Va ues in brackets Specifications subject Mexico: 01-800-733-8926 Japan: 81-44-844-8013
www.tycoe ectronics.com are metric equiva ents. to change. C. America: 52-55-1106-0803 UK: 44-8706-080-208
KILOVAC High Vo tage DC Contactors
KILOVAC High Voltage DC Contactors
7
For factory-direct application assistance,
dial 00-253-4560, ext. 2055, or
05-220-2055.
Product Facts
ILatching version of popular
EV200 Series
IDesigned to be the
smallest, lowest cost,
lightest weight sealed
contactor in the industry at
its current rating
IOptional auxiliary contacts
for monitoring position of
power contacts
IHermetically sealed —
operates in explosive/harsh
environments with no
oxidation or contamination
of coil or contacts during
long periods of non-
operation
INot position sensitive, can
be mounted in any
orientation
KILOVAC EV200P Series Latching Contactor With 1 Form X (SPST Latch)
Contacts Rated 500+ Amps, 12-900 Vdc
Ordering Information
Typical art Number 䊳EV200 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 = Non
Mounting & ower Terminals:
A = Bottom Mount & Mal 10mm x
M8 Thr ad d T rminals
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 (.0 3 G2/Hz)
Operating Temperature Range —
-40°C to + 5°C
Electrical Data
Voltage Rating —
Main Contacts (Max) — 750 Vdc
Current Rating, Continuous —
Main Contacts 2— 500A
Contact Resistance —
Main Contacts 3—
0.2 mΩmax above 300A
0.3 mΩmax between 50 and 300A
Hot Switching Performance
(Positive Polarity) 4—
200A make/ break @ 270Vdc —
10,000 cycles
600A make/ break @ 360Vdc —
100 cycles
00A break only @ 360Vdc —
15 cycles
2000A break only @ 360Vdc — 1 cycle
Mechanical Life (Min) —
100,000 cycles
Dielectric Withstand Voltage —
Terminal to Terminal/ Terminals to Coil —
1mA max @ 2,200 Vrms
Insulation Resistance —
Terminal to Terminal/ Terminals to Coil —
100MΩmin @ 500Vdc new
50MΩmin @ 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:
1Product can be configured alter-
nately with form B or auxiliary
switches if required. This changes
the product part number, depend-
ing on specific auxiliary configura-
tion. onsult Tyco Electronics for
availability and part number
2Ambient conditions and conductor
design affect rating. Terminal tem-
perature rise should be 75° max
above ambient. Keep relay termi-
nals below 150° max continuous,
175° max for two hours, and
200° for 1 minute.
3Stabilized reading. ontact resist-
ance may exceed spec in the first
10 minutes of current carry.
4Units are polarity sensitive.
Approximately 50% de-rating
for reverse polarity switching.
onsult factory for review of
specific requirements.
5Over temperature range unless
noted. Suggested coil pulse =
50-100 ms.
624V and 48V coils available on
request — consult factory.
7Intermittent Duty oil. oil over-
heating can occur if duty cycle is
exceeded. Limit average coil power
to 10W maximum.