HIGH VOLTAGE AND CURRENT CUT-OFF CAPACITY IN A COMPACT PACKAGE

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Marsha Jennings
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HIGH VOLTAGE AND CURRENT CUT-OFF CAPACITY IN A COMPACT PACKAGE RELAYS (60A type only) A PC board type A TM type 60A Screw terminal type 80A Connector type 300A Connector type Compliance with RoHS

High-, high-current control capable 0V DC high- switching cutoff has been achieved thanks to a sealed construction with mixed hydrogen gas and the magnetic arc motion through use of a permanent

There is little operating sound, which does not change even when large currents are cut off. 3.

Safety Since the contacts are enclosed in a sealed capsule structure, the arc will not get out, which ensures safety. 5.

Mounting direction is not specified The weight of the movable parts is light, and also the restoring force is large, hence the relay is relatively unaffected by gravity. 7.

1 HIGH VOLTAGE AND CURRENT CUT-OFF CAPACITY IN A COMPACT PACKAGE RELAYS (60A type only) A PC board type A TM type 60A Screw terminal type 80A Connector type 300A Connector type Compliance with RoHS Directive FEATURES. High-, high-current control capable 0V DC high- switching cutoff has been achieved thanks to a sealed construction with mixed hydrogen gas and the 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 sound, which does not change even when large currents are cut off. 3. Arc space unnecessary The enclosure box can be made smaller thanks to an arc-space-free construction from 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 relay is relatively unaffected by gravity. 7. Wide selection of models available. Types include PC board type, TM type (A), screw terminal type (60A), and connector type (80A and 300A). 8. Standard compliance The 60A type is UL and C-UL standard certified. TYPICAL APPLICATIONS. Cogeneration systems. Battery inspection and testing equipment (charge and discharge control) 3. Construction machinery 4. AGV (Automatic guided vehicle) (Unmanned transport carts) 5. Welding equipment 6. Inverter control 7. Solar power generation systems 8. Elevator, etc. ORDERING INFORMATION Relay Contact arrangement : Form A 3: Form A PC board type* 5: Form A TM type* Contact rating : A 6: 60A 8: 80A 9: 300A Coil : V DC 4: 4V DC 48: 48V DC* X0: 0V DC* Note: *A type only A 0

2 TYPES A PC board type Ttpe Nominal coil Contact arrangement Part No. Notes: * One female connector lead wire for connecting is packaged with the 80A and 300A connector types. -Specifications: Housing: Yazaki 783- (light gray); Lead wire: 0.5 mm dia. and 300± mm length Lead wire coating color: Pin No. : white; Pin No. : green Carton Packing quantity 60A V DC A60 pc. pcs. A TM type A54 5pcs. 0pcs. Form A 60A 4V DC A604 pc. pcs. 80A Connector type* A804 pc. pcs. 300A Connector type* A904 pc. 5pcs. A PC board type A348 5pcs. 0pcs. 48V DC A TM type A548 5pcs. 0pcs. A PC board type A3X0 5pcs. 0pcs. 0V DC A TM type A5X0 5pcs. 0pcs. Case A3 5pcs. 0pcs. A TM type A5 5pcs. 0pcs. 80A Connector type* A80 pc. pcs. 300A Connector type* A90 pc. 5pcs. A PC board type A34 5pcs. 0pcs. RATING. Coil data Type Nominal coil Pick-up (at C 68 F) Drop-out (at C 68 F) *When using a DC power supply use one that has a leeway of at least 50% current capacity. Nominal coil current [±%] (at C 68 F) Nominal operating power (Nominal applied to the coil, at C 68 F) A 0.3A Max..4W 60A 0.45A Max. 5W 80A V DC 0.375A Max. 5W When input: W max. 300A 3.3A (during peak) (0. sec. from time of input) When retained: 4 W max. A 75%V or less of 8%V or more of 0.05A Max..4W nominal nominal 60A (Initial) (Initial) 0.8A Max. 5W 80A 4V DC 0.88A Max. 5W When input: 45 W max. 300A.85A (during peak) (0. sec. from time of input) When retained: 4 W max. A 48V DC 0.06A A 0V DC 0.0A Max..4W Max. allowable 30%V of nominal

3 . Specifications Characteristics Item Specifications A type 60A type 80A type 300A type Arrangement Form A Form A Form A Form A Nominal switching capacity () A 0V DC 60A 0V DC 80A 0V DC 300A 0V DC Rating Electrical characteristics Mechanical characteristics Expected life Short term current 5A (min), 30A (30s) A (5min) (harness wire: 5mm ) Notes: * The upper operation ambient temperature limit is the maximum temperature that can satisfy the coil temperature rise value. Refer to 6. Conditions for operation, transport and storage mentioned in AMBIENT ENVIRONMENT. * Conditions: Varistor used for coil surge absorption. Note: if a diode is used the life will be lower. *3 Condition: Switches rated number of cycles each time there is a,500a cutoff. 0A (min) (harness wire: 0mm ) Max. cut-off current 600A 300V DC 800A 300V DC,500A 300V DC (5 cycles)* ( cycle)* (3 cycles)* 3 Overload opening/closing rating 30A 0V DC 80A 0V DC A 0V DC 600A 0V DC (Min. 50 cycles)* (Min. 0 cycles)* (Min. 50 cycles)* (Min. 300 cycles) Reverse cut-off current A 0V DC 60A 0V DC A 0V DC 300A 0V DC (Min..5 3 cycles)* (Min.,000 cycles)* (Min. 50 cycles)* (Min. 0 cycles) Min. switching capacity A 6V DC Contact drop Insulation resistance (Initial) Breakdown (Initial) Operate time (at C 68 F) Release time (at C 68 F) Between open contacts Between contact and coil Max. 0.5V (When current [is A per ] contact set) Max. 0.V (When current [is 60A per ] contact set) Max V (By drop 6V DC A) Min. 0MΩ (at 500V DC) Measurement at same location as Initial breakdown section.,500 Vrms for min. (Detection current: ma.),500 Vrms for min. (Detection current: ma.) Max. 50ms (Nominal applied to the coil, excluding contact bounce time.) Max. 30ms (After the nominal operation stops) Max. 0.06V (When current [is 300A per ] contact set) Max. 30ms (Nominal applied to the coil, excluding contact bounce time.) Max. ms (After the nominal operation stops) Shock resistance Functional Min. 96 m/s (Half-wave pulse of sine wave: ms; detection time: µs.) Destructive Min. 490 m/s (Half-wave pulse of sine wave: 6 ms.) Vibration resistance Functional to 0Hz, acceleration 43m/s constant (Detection time: µs.) Destructive to 0Hz, acceleration 43m/s constant (3 directions,each 4 hours) Mechanical Min. 5 Min Electrical A 0V DC* 60A 0V DC* 80A 0V DC* 300A 0V DC L/R ms L/R ms L/R ms L/R ms Ambient temperature: C to +80 C F to +76 F (Storage: Max. 85 C 85 F), Conditions Conditions for operation, transport and storage* Humidity: 5 to 85% R.H. (Not freezing and condensing at low temperature) Unit weight Approx. 80 g.8oz Approx. 3 g.00oz Approx. 0 g 4.oz Approx. 750 g 6.46oz REFERENCE DATA.-() Ambient temperature characteristics (A type) Tested sample: A type relay, 3pcs.-() Ambient temperature characteristics (60A type) Tested sample: 60A type relay, 3pcs.-(3) Ambient temperature characteristics (80A type) Tested sample: 80A type relay, 3pcs Ambient temperature, C F Pick up Variation ratio, % x Drop out Variation ratio, % 30 Ambient temperature, C F Pick up Drop out x x Release time Ambient temperature, C F - -4 Variation ratio, % 0 3 Pick up Drop out Operate time

4 .-(4) Ambient temperature characteristics (300A type) Tested sample: 300A type relay, 3pcs.-() Max. value for switching capacity (A and 60A types).-() Max. value for switching capacity (80A and 300A types) Variation ratio, % 30 Release time Ambient temperature, C F Operate time Drop out 74 Pick up A type 0V DC, A type 0V DC, A type 0V DC, 300A type 0V DC, Contact, V 0 00 Contact, V 3.-() Switching life curve (A type) 3.-() Switching life curve (60A type) 3.-(3) Switching life curve (80A type) Life (cycle) A type 0V DC, Life ( 3 cycle) 60A type 0VDC, Life (cycle) A type 0V DC, (4) Switching life curve (300A type) 4. Cut-off curve (forward direction) 5.-() Carrying performance curve (80 C) (A and 60A types) A type 0V DC, (However, 300V DC when 900A is exceeded.) 5 4 Life (cycle) 00 Life (cycle) 0 Time, sec A type 0V DC, A type 0V DC, 80A type 0V DC, Cut-off current, A 0 A type (Electric cable mm ) 60A type (Electric cable 5 mm ) 0 00 Carrying current, A 5.-() Carrying performance curve (80 C) (80A and 300A types) A type (Electric cable 5 mm ) 300A type (Electric cable 0 mm ) Time, sec Carrying current, A

5 DIMENSIONS (Unit: mm inch). A PC board type Schematic (Bottom view) :Coil :Coil Load sides have polarities (+) and ( ). 6.5 ± ±.0 Max..394 ±0.3 ± to ±0.6 ±.04 Min ±.0 ±.039 dia. dia..079 dia..079 dia max max ±0.3. ± ± ± ± ±.0 Coil input terminal R ± ± (.0) (.039) PC board pattern (Bottom view) Mounting hole -4. dia dia. After doing through-hole plating dia dia Notes:. We recommend through-hole plating with land on both sides.. Be careful of the insulation distance between land patterns with regards to the circuit you will use.. A TM type Schematic (Top view) Load input terminal (+) #87 tab 0.5t 4.5 ±0. dia..000 ±.008 dia. Load input terminal ( ) #87 tab 0.5t 45 max..77 max ±0.3. ± Coil input terminal #87 tab 0.5t.3 ± ± ± ± :Coil 6:Coil Load sides have polarities (+) and ( ). Panel cut-off Mounting hole -4. ±0. dia ±.004 dia ±0.. ± Max..394 ±0.3 ± to ±0.6 ±.04 Min ±.0 ±.039

6 3. 60A type Schematic (Top view) ±0.. ± (7.9) (.705) ±0. dia. -.7 ±.004 dia. + 6: Coil 5: Coil Load side has polarities (+) and ( ). Coil input terminal (M3.5) ± ± Bus bar (5sq) M4 screw M5 screw Panel cut-off dia dia (terminal height) (terminal height) Plate (Part No., rating, schematic and Lot No.) Max..394 ±0.3 ± to ±0.6 ±.04 Min ±.0 ± A type Schematic (Top view) (width of bus bar) (ends of bus bar) (M5 bolt pitch) (7.9) (.705) dia. (flat washer) Panel cut-off Coil Coil + Load sides have polarities (+) and ( ) dia..36 dia. ( ) (M4) (M.57) (+) M5 bolt M.97 bolt Connector Part No.: 78- (Yazaki)* -6 dia dia *Accessories (included) ±.8± sq/White (5) (.97) 0.5sq/Green Female connector (non-waterproof type), Yazaki 783- Color height (connector position) Plate (Product name, Part No. and Lot No.) Max..394: ±0.3 ± to : ±0.6 ±.04 Min : ±.0 ±.039

7 A type Schematic (Top view) DC + polarity ±0.3 3.± : Coil (GND) 5: Coil (V+) + Input and load sides have polarities (+) and ( ). + - DC polarity Panel cut-off ± ± Connector Part No.: 78- (Yazaki)* (3) (.5) 3.8 M8.35 bolt M8.35 Flange nut Plate (rear side) (Product name, Part No. and Lot No.) No.6 terminal: Coil, GND No.5 terminal: Coil, V+ 3-6±0.3 dia ±.0 dia dia dia. *Accessories (included) 300±.8± sq/White Max..394: ±0.3 ± to : ±0.6 ±.04 Min : ±.0 ±.039 (5) (.97) sq/Green Female connector (non-waterproof type), Yazaki 783-

8 NOTES. 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. M5 screw (60A, 80A and 300A main unit mounting section): 3 to 4N m M3.5 screw (60A input terminal): 0.84 to. N m M4 screw (A PC board type main unit mounting section): 0.98 to.n m (A TM type main unit mounting section):.8 to.7n m Recommended securing torque on load side terminals 60A/M5 screw:.5 to 3.6 N m 80A/M5 bolt: 3.5 to 6.5 N m 300A/M8 bolt: to N m. The contacts of the relay are polarized. Please follow instructions in the connection schematic when connecting the contacts. We recommend installing a surge protector varistor (ZNR) for the A, 60A and 80A types. Avoid using a diode as this may result in decreased cut-off capability. 3. 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 and from the point of view of safety, consider installing a failsafe circuit in the device. Also, in order to avoid increased contact resistance, do not operate when there is no switching load. 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, and the ambient storage temperature is between and 85 C and +85 F. 7. Do not disassemble the relay. Please note that disassembling the relay will invalidate the warranty. 8. 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. 9. Coil operating power Pure DC current should be applied to the coil. The wave form should be rectangular. If it includes ripple, the ripple factor should be less than 5%. However, check the actual circuit since the characteristics may be slightly different. The power supply waveform supplied to the coil should be rectangular.. Don t exceed maximum coil. Exceeding maximum allowable coil on continuous basis will damage the relay and could case failure.. Ensure that the rated contacts and current values are not exceeded.. The rated control capacity and life are given as general guides. The contact life is heavily influenced by the type of load and other related conditions, and these factors must be kept in consideration when using the relay. 3. Main contact ratings in the ratings apply to when there is a. 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. 4. 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. A TM type: Faston terminal for #87 tab terminal, 0.5 mm board thickness (JIS C compliant, flat type connection terminal) Harness nominal cross-sectional area Load input terminal: min..0 mm Coil input terminal: min. 0.3 mm 60A and 80A types: Min. 4mm nominal cross sectional area 300A type: Min. 0mm nominal cross sectional area 5. Use N to 70N of force as a guide to fasten the terminal connected to the A TM type. Please use caution when inserting or removing the terminal as the relay tab terminal may cause injuly. 6. Place the PC board mount type (A PC board type) securely by hand soldering after attaching it using M4 screw. Don t submerge assembled board in cleaning solvent or water. Also, be careful not let flux overflow up from the PC board or adhere to the base of the relay. Recommended hand soldering conditions Soldering iron: 30 to 60 W Tip temperature: 0 C 75 F Solder time: within approx. 5 seconds 7. Make sure the power is turned off when wiring. 8. Incorrect wiring may cause unexpected malfunction and failure. 9. Regarding AC cutoff, although there is no contact polarity, generally it is thought that the electrical life will shorten due to cutoff in the reverse direction, compared to DC cutoff. Confirm electrical life using actual load. In the case of DC cut-off, please note the contact polarity.. Lead-free solder (tin, silver and copper) is used as pre-solder for the terminals of the PC board mount type (A PC board type).. The warranted tensile strength of the female connector lead wire used for connection that comes with the 80A and 300A connector type when attaching it to the relay body is 0N. Avoid excessive tension as this is a cause of broken wires and damage. Also, insert the female connector deeply and make sure the connection is secure. For Cautions for Use, see Relay Technical Information.

HIGH VOLTAGE AND CURRENT CUT-OFF CAPACITY IN A COMPACT PACKAGE

HIGH VOLTAGE AND CURRENT CUT-OFF CAPACITY IN A COMPACT PACKAGE RELAYS (60A type only) 0A PC board type 0A TM type 60A Screw terminal type 80A Connector type 300A Connector type FEATURES. High-, high-current