CAPSULE CONTACT MECHANISM AND HIGH-CAPACITY CUTOFF COMPACT RELAY FEATURES
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1 CAPSULE CONTACT MECHANISM AND HIGH-CAPACITY CUTOFF COMPACT RELAY EV RELAYS (AEV) 80A A 0A FEATURES. High-, high-current control possible 0 high- switching cutoff has been achieved thanks to a sealed construction with mixed hydrogen gas and magnetic arc motion through use of a permanent magnet.. Compact & low Operating Sound By using a capsule contact mechanism that is enclosed with hydrogen gas, highcapacity cutoff is possible even with a tiny contact gap. There is little operating noise, which does not change even when large currents are cut off. 3. Arc space unnecessary The enclosure box has been made smaller thanks to an arc-space-free construction in which the arc will not get out. 4. Safety Since the contacts are enclosed in a sealed capsule structure, the arc will not get out, which ensures safety. 5. High contact reliability The contact part is hermetically sealed with H mixed gas, hence the contact resistance remains stable regardless of the ambient conditions. 6. 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. 7. Coil 4 type is also available TYPICAL APPLICATIONS Electric Vehicle Hybrid Electric Vehicle Fuel-cell vehicle Construction machinery AGV (Automatic guided vehicle) (Unmanned transport carts) Battery inspection and testing equipment (charge and discharge control) SPECIFICATIONS Contact Type A type 80A type 0A type Arrangement Form A Form A Form A Rating Expected life (min. operations) Nominal switching capacity (resistive load) A 0 80A 0 0A 0 Short term current 5A (min), A (sec)(mm ) A (5min)(5mm ) 0A (min)(0mm ) Min. switching capacity # A Max. cut-off current 800A 0 ( cycles) #3,500A 0 (3 cycles) # Overload opening/closing rating A 0 (50 cycles) #3 A 0 (50 cycles) #3 600A 0 (0 cycles) Reverse direction cut-off -A 0 (.5x 4 cycles) #3 -A 0 (50 cycles) #3 0A 0 (0 cycles) Contact drop Max. 0.5V (When current is A per contact set) Max V (When current is A per contact set) Max. 0.06V (When current is 0A per contact set) Mechanical Electrical A A 0 3 0A 0 3 (L/R & ms) # (L/R & ms) # (L/R & ms) Notes # 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. # Condition: Nominal switching cycles,each cut off,500 A. #3 The electrical load performance value for the A and s 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. #4 The coil type and 4 type have the same specifications. ds_63_0000_en_ev: 0506J
2 Characteristics Initial insulation resistance Min. 0MΩ (at 500 ) * Initial breakdown Operate (at C 68 F) Release (without diode) (at C 68 F) Shock resistance Vibration resistance Conditions for operation, transport and storage (Not freezing and condensing at low temperature) Mass Remarks * Measurement at same location as "Initial breakdown " section. * Detection current: ma *3 Excluding contact bounce *4 Nominal applied to the coil. *5 Half-wave pulse of sine wave: ms; detection : ms *6 Half-wave pulse of sine wave: 6ms *7 Detection : ms *8 Time of vibration for each direction; X, Y, Z direction: 4 hours *9 Storage: Max.85 C 85 F. ORDERING INFORMATION Between open contacts AC,500 Vrms for min. * Between contact and coil AC,500 Vrms for min. * Functional For A type: Max. 50ms *3 For 80A type: Max. 50ms *3 For 0A type: Max. ms *3 For A type: Max. ms *4 For 80A type: Max. ms *4 For 0A type: Max. ms *4 For A type: Min. 96m/s { G} *5 For 80A, 0A type (ON): Min. 96m/s { G} *5 For 80A, 0A type (OFF): Min. 98m/s { G} *5 Destructive Min. 490 m/s {50 G} *6 Functional Destructive temperature Humidity Ex. A EV 0 For A, 80A type: Hz to 0 Hz, Min.43 m/s {4.4 G} *7 For 0A type: Hz to 0 Hz, Min.44 m/s {4.5 G} *7 For A, 80A type: Hz to 0 Hz, Min.43 m/s {4.4 G} *8 For 0A type: Hz to 0 Hz, Min.44 m/s {4.5 G} *8 For A, 80A type: C to +80 C to +76 F *9 For 0A type: C to +85 C to +85 F *9 5% R.H. to 85% R.H. A type: 80g.8 oz 80A type: 0g 4. oz 0A type: 750g 6.46 oz Product Name Contact arrangement Contact rating Coil Coil terminal structure EV : Form A : A 8: 80 A 9: 0 A : 4: 4 Nil: Connector (80 A, 0 A) : Plug-in (with terminal protection cover, A) PACKING QUANTITY Types Inner Outer A Form A 5pcs. 0pcs. 80A Form A pc. pcs. 0A Form A pc. 5pcs. TYPES AND COIL DATA (at C 68 F) Type Part No. Coil, Pick-up,, Nominal coil current Operating power, W (V and 4) A AEV Min A ±% Max..4 W 80A AEV80 Min A ±% Max. 4.5 W 0A AEV90 Max. 9 Max. W 3.3 A ±% Min. (Inrush, approx. 0. sec.) (at peak) Max. 4 W (Stable) A AEV4 Min A ±% Max..4 W 80A AEV804 Min A ±% Max. 4.5 W 4 Max. 8 Max. 45 W.85 A ±% 0A AEV904 Min. 4 (Inrush, approx. 0. sec.) (at peak) Max. 4 W (Stable) Max. allowable, 6 3 ds_63_0000_en_ev: 0506J
3 DIMENSIONS. A Load input terminal (+) ± ± ±0.3.± Coil input terminal 4.± ±.0 EV (AEV) mm inch 5:Coil 6:Coil Load side has polarities (+) and (-) 4.5±0. dia..77±.008 dia. Load input terminal ( ) MAX. 45 MAX Mounting hole -4.±0. dia. -.65±.004 dia. 55.9±0..± less than (.394) ±0.3 (±.0) (.394) to 50 (.969) ±0.6 (±.04) more than 50 (.969) ±.0 (±.039). 80A (Bus bar width) dia..36 dia. ( ) (Both ends of bus bar) (M5 bolt pitch) (M.97) (7.9) (.705) (M4) (M.57) 8.0 dia.(flat washer).35 dia. (+) M5 bolt M Polarity DC -Connector part number: 78- (Yazaki) (Supplement) harness side Female connector part number: 783- Coil Coil Load side has polarities (+) and (-) dia -.36 dia less than (.394) ±0.3 (±.0) (.394) to 50 (.969) ±0.6 (±.04) more than 50 (.969) ±.0 (±.039).47 Collar height: (Connector position) Plate (Product name, Part number and Lot number) ds_63_0000_en_ev: 0506J 3
4 5 6 EV (AEV) 3. 0A Polarity DC ± ± ±0.3 3.± Connector part number: 78- (Yazaki) No. 6 terminal: Coil GND (Supplement) harness side No. 5 terminal: Coil V + Female connector part number: 783- (Yazaki) M8 bolt M8 Flange nut (3) (.59) + - Polarity DC - 3-6±0.3 dia ±.0 dia. 6:Coil(GND) 5:Coil(V ) Both input and load sides have polarities (+) and (-) dia dia Plate (rear) (Product name, Part number and Lot number) less than (.394) ±0.3 (±.0) (.394) to 50 (.969) ±0.6 (±.04) more than 50 (.969) ±.0 (±.039) REFERENCE DATA -() temperature characteristics ( A) Sample: EV relay A, 3 pcs -() temperature characteristics (80 A) Sample: EV relay 80 A, 3 pcs -(3) temperature characteristics (0 A) Sample: EV relay 0 A, 3 pcs Release Operate Release Operate Max. value for switching capacity 3. Switching life curve 4. Cut-off life curve Contact current, A resistive load 0 resistive load A type 0 V AC, DC resistive load 0 00 Contact, V Life, cycle A type 0 V AC, DC resistive load 0 resistive load 0 resistive load 0 00 Contact current, A Life, cycle resistive load (Min. 600 A: 0 ) 0 resistive load (Min. 900 A: 0 ) Cut-off current, A 4 ds_63_0000_en_ev: 0506J
5 5. Carrying performance curve (80 C 76 F) Time, sec 00 A type Carrying current, A NOTES. 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. M4 screw ( A):.8 to.7 N m M5 screw (80 A, 0 A): 3 to 4 N m M8 nut (): to N m. The coils () and contacts (all type) of the relay are polarized, so follow the connection schematic when connecting the coils and contacts. Type 0 A contains a reverse surge absorption circuit; therefore a surge protector is not needed. We recommend installing a surge protector varistor (ZNR) for the A, 80 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- direct-current switch. In its final breakdown mode, it may lose the ability to provide the proper cut-off. Therefore, do not exceed the indicated switching capacity and life. (Please treat the relay as a product with limited life and replace it when necessary.) In the event that the relay loses cut-off ability, there is a possibility that burning may spread to surrounding parts, so configure the layout so that the power is turned off within one second. 6. Permeation life of internal gas This relay uses a hermetically encased contact (capsule contact) with gas inside. The gas has a permeation life that is affected by the temperature inside the capsule contact (ambient temperature + temperature rise due to flow of electrical current). For this reason, make sure the ambient operating temperature is between and 80 C and +76 F (0A type is Max. 85 C 85 F), and the ambient storage temperature is between and 85 C and +85 F. 7. If the power is turned off and then immediately on after applying the rated (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 to rise, and possibly exceed the rated pick-up. In these circumstances, take measures such as reducing the load current, limiting the duration of current flow, and applying a coil higher than the rated operating. 8. 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 > 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. 9. For the, drive the coil with a quick startup. (Built-in one-shot pulse generator circuit). Be careful that foreign matter and oils and fats don t stick to the main terminal part because it is likely to cause a terminal part to give off unusual heat. Also, please use the following for connected harnesses and bus bars. A type: Min. mm nominal crosssectional : Min. 5 mm nominal crosssectional : Min. 0 mm nominal crosssectional. As a guide, the insertion strength of the plug-in terminal into the A type relay tab terminal should be to 70 N. Please select a plug-in terminal (flat connection terminal) for #87 tab terminals that have a plate thickness of 0.5 and which comply with JIS C 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. 3. Use the specified connector for the connector terminal connection (80 A and 0 A) Yazaki Corporation 783 or equivalent 4. After the ON signal enters the 0A type, automatic coil current switching occurs after approximately 0. seconds. Do not repeatedly turn it OFF within that 0. seconds interval, as doing so may damage the relay. For Cautions for Use, see Relay Technical Information. ds_63_0000_en_ev: 0506J 5
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