1618408-5

KILOVAC KCS03 Current-Sensing High-Voltage Contactor 600 A/28 VDC – 600 VDC Bi-Directional Power Switching in a Rugged, Compact Package with Integrated Current Sensor and Current Trip Function AEROSPACE, DEFENSE & MARINE /// KCS03 CURRENT SENSING CONTACTOR KILOVAC KCS03 Current-Sensing High-Voltage Contactor Compact Package with Integrated Current Sensor and Current Trip Function The new KILOVAC Current Sensing [KCS] Contactors from TE Connectivity (TE) eliminate the need for a discrete current sensor, saving the customer money, weight and space. The sensor function also has a programmable trip feature, allowing for immediate, delayed or disabled trip. Rugged Reliability INTEGRATED CURRENT SENSOR • Saves space by eliminating the need for external sensor • Simplifies design • Flexible configuration for application needs HERMETICALLY SEALED • Suitable for application in harsh, explosive, and corrosive environments • No oxidation or contamination of contacts, including long periods of non-operation SPACE AND WEIGHT SAVINGS • Extremely small size • Lightweight contactor: 500 grams VERSATILE • Bidirectional switching • Main contacts not polarity sensitive • Not position sensitive: mounts in any orientation EFFICIENT • Integrated dual-coil electronic economizer with coil suppression • EMC compliant: no radiated coil emissions APPLICATIONS • Energy Storage/Battery Storage • Power Distribution • Power Motion Control • High-Voltage DC Converter Systems • Alternative Energy • Military and Commercial Electric Vehicles • Test Equipment In addition to the integrated current sensing feature, KSC03 contactors are rugged and hermetically sealed, making them suitable for a variety of applications in harsh, corrosive and explosive environments. Even after long periods of non-operation, the contacts are impervious to oxidation and contamination. Versatile and Efficient The KCS03 contactor is extremely small and lightweight. It features bidirectional switching and an integrated dual-coil electronic economizer with coil suppression, and can be mounted in any orientation. Main contacts are not polarity sensitive, and the KSC03 is EMC compliant with no radiated coil emissions. Specifications MAIN CONTACTS • Contact Arrangement: SPST-NO (Form X) • Voltage Rating, Switching: 600 VDC max. • Current Rating, Continuous: ±600 A • Current Rating, Short Term: ±1200 A / 30 sec • Contact Resistance, Main Contacts: 0.2 mΩ max. at rated current •H  ot-Switching Performance, Resistive Load 1 A / 600 VDC: 1,000,000 cycles 100 A / 28 VDC: 100,000 cycles 100 A / 400 VDC: 25,000 cycles 100 A / 600 VDC: 20,000 cycles 1000 A / 28 VDC: 100 cycles 1000 A / 400 VDC: 10 cycles 1000 A / 600 VDC: 5 cycles • Maximum Pulse Through Closed Contacts: 3000 A (half cycle, 60 Hz) •D  ielectric Withstanding Voltage: Between Open Contacts: 2800 Vrms Contacts to Coil: 2800 Vrms / 4000 VDC • Insulation Resistance (Terminal to Terminal; Terminals to Coil): Beginning of Life 100 MΩ min. @ 500 VDC End of Life 50 MΩ min. @ 500 VDC TE Components . . . TE Technology . . . TE Know-how . . . AMP | AGASTAT | CII | HARTMAN | KILOVAC | MICRODOT | NANONICS | POLAMCO | Raychem | Rochester | DEUTSCH SEACON Phoenix | LL ROWE | Phoenix Optix | AFP | SEACON Get your product to market faster with a smarter, better solution. AEROSPACE, DEFENSE & MARINE /// KCS03 CURRENT SENSING CONTACTOR PAGE 2 KILOVAC KCS03 Current-Sensing Contactor AUXILIARY CONTACTS MECHANICAL/ENVIRONMENTAL •A  uxiliary Contacts Contact Arrangement: SPST-NO (Form A) • Auxiliary Contact Rating: 1 A/ 30VDC, 3 A/125 Vac • Switching Life at Max. Rating: 100,000 cycles min. • Minimum Load: 5 VDC/5 mA • • • • • • • Mechanical Life: 1,000,000 cycles Shock: 11 ms 1/2 sine (operating), 20 g peak Sine Vibration: 20 g peak (operating), 55-2000 Hz Operating Temperature Range: -40 to +105 °C RoHS Compliant Weight, Nominal: 500 grams Hermetically Sealed: Safe for harsh/corrosive environments • Nonoxidizing: No contact oxidation over periods of nonuse • Mounting: Not position-sensitive • Noise Emission (at 100 mm distance): 70 dBa Coil Data At 20°C (Internal Two-Coil Economizer) 12 V Coil 24/28 V Coil Coil Voltage Range 9-14 VDC 18-28 VDC Nominal Pickup Current 4.5 A 4.5 A Nominal Holding Current 0.26 A 0.23 A Pickup Voltage ≥9 VDC ≥16 VDC Dropout Voltage ≤3.5 VDC ≤10 VDC Pickup Pulse (max) 50 ms 50 ms Coil Resistance ±5% Coil Holding Power 2.0 Ω Pickup/45 Ω Hold 3.2 W 5.7 Ω Pickup/120 Ω Hold 5.5 W Operate Time (max) 20 ms 20 ms Operate Bounce (max) 3 ms 3 ms Release Time 5 ms 5 ms Sensing Range (5% accurate -40°C to +105°C) ±50 – 630 A ±50 – 630 A Null Output @ I = 0 2.5 (±0.04) VDC Main Contacts: Current Sensing Output Voltage vs. Current (VDC) 2.5 (±0.04) VDC V(I) = ±I (.0034) + 2.50 Current Trip Point vs. Setpoint Resistance See Pages 5 and 6 Hysteresis (-40°C to + 105°C) 1% of Full Scale Output AEROSPACE, DEFENSE & MARINE /// KCS03 CURRENT SENSING CONTACTOR PAGE 3 KILOVAC KCS03 Current-Sensing Contactor Ø2.29 [58.17] HARNESS: WIRE LENGTHS 15" NOMINAL ALL CONDUCTORS M22759/11, 22 AWG RED = V+ BLACK = RTN WHITE (2 EA) AUX COM-NO PURPLE = TRIP DISABLE/PROGRAM TIME DELAY ORANGE = CONNECT TO V+ FOR TRIP SENSING AND CURRENT SENSING BROWN = CURRRENT SENSE OUTPUT BLUE = Rx YELLOW = Rx Ø0.23 [5.84] 1.05 [26.67] 2.69 [68.33] OBSERVE PROPER POLARITIES FOR CONTROL LINES UNTERMINATED WIRES - USE ESD HANDLING PROCEDURES 3.17 [80.52] M5 x 1.25 NUT HARDWARE INCLUDES FLAT WASHER AND LOCKWASHER MAX. TORQUE: 90 IN-LBS. [10 N-m] CURRENT FLOW INTO THIS TERMINAL FOR INCREASING SENSOR OUTPUT >2.5 VDC 0.50 [12.7] 2.87 [72.9] Part Numbering System KCS 03 X 024E A A A SERIES KCS KILOVAC Current Sensing SIZE 03 Size 03 (EV200 Package) CONFIGURATION X Form X, Normally Open COIL VOLTAGE 012E 12 V Coil Economized 024E 24 V Coil Economized COIL LEAD LENGTH A 15 Inch Coil Leads MOUNTING HARDWARE A M8 Male Terminals MOUNTING STYLE A Bottom Mount Part Numbers Coil Voltage Part No. 12 VDC KCS03X012EAAA 24 VDC KCS03X024EAAA AEROSPACE, DEFENSE & MARINE /// KCS03 CURRENT SENSING CONTACTOR PAGE 4 KILOVAC KCS03 Current-Sensing Contactor Load Life: Resistive Load Switching 1,000,000 Cycles 100,000 10,000 1000 100 400V 600V 28V 10 1 1 10 100 1000 Current (A) Current Carry vs. Time 10,000 Time (s) 1000 Time Rate 100 10 1 0.1 0.01 0 500 1000 1500 2000 2500 3000 3500 Current (A) Trip Function/Trip Delay 650 600 550 500 Trip Current (A) 450 400 350 300 250 200 150 100 50 0 0 1000 2000 3000 4000 External Resistor Value (Ohms) 5000 AEROSPACE, DEFENSE & MARINE /// KCS03 CURRENT SENSING CONTACTOR 6000 PAGE 5 KILOVAC KCS03 Current-Sensing Contactor Trip Setpoint Resistor (10 A to 150 A) Connect Rx across Blue and Yellow for Trip Setpoint Connect Purple to RTN to Disable Trip Function or Connect Purple to External Capacitor Tied to RTN to Delay Trip, 7 ms/µF Connect Orange to V+ To Enable Trip and Current Sensing Reset Tripped Contacts by Cycling V+ Off to On Intrinsic Trip Delay (Blue/Yellow Not Connected to Rx) = 14 ms Input Output Control (Orange) V+ (Red) RTN (Black) Main Contact Current (A) Trip Disable/ Time Delay (Purple) Trip Set Rx (Blue) Trip Set Ax (Yellow) 0 Vnom 0 0 NON-ACTIVE NON-ACTIVE 0 ON (NO TD) 0 0 0 0 NON-ACTIVE NON-ACTIVE 0 OFF(NO TD) 1 0 0 0 OPEN OPEN 2.5 OFF RELAY TRIP OPEN AFTER 14 ms Hall Output (V) ( White) Main Contacts Top Post 1 Vnom 0 180 A ±7% OPEN 30K 4.84 (2.5 when relay trip) 1 0 then 1 remove and re-apply power 0 ≤167 A OPEN 30K 2.5 ON (NO TD) 1 Vnom 0 0 1 Vnom 0 180 A ±7% 1 0 0 0 1 Vnom 0 1 Vnom 1 1 GND (TRIP DISABLE) GND (TRIP DISABLE) GND (TRIP DISABLE) X 2.5 ON (NO TD) X 4.84 ON (NO TD) X 2.5 OFF(NO TD) 0 1 µF is added between Purple and RTN 30K 2.5 ON (NO TD) 0 180 A ±7% 10 µF is added between Purple and RTN 30K 4.84 (2.5 when relay trip) RELAY TRIP OPEN AFTER 82 ms Vnom 0 180 A ±7% 10 µF is added between Purple and RTN 30K 4.84 (2.5 when relay trip) RELAY TRIP OPEN AFTER 720 ms 0 then Vnom remove and re-apply power 0 ≤167 A 10 µF is added between Purple and RTN 30K 2.5 ON (NO TD) AEROSPACE, DEFENSE & MARINE /// KCS03 CURRENT SENSING CONTACTOR PAGE 6 KILOVAC KCS03 Current-Sensing Contactor Timing Diagram Vcontrol (0range) 0V V+in (Red) 0V I trip I (Contacts) 0A Closed Contacts Open >14 ms 14 ms Connection Diagram GND ENERGIZE/CLOSE CONTACTS USING SWITCH OR SOLID STATE DEVICE-LOW SIDE DRIVE SHOWN KCS03X012/KCS03X024 RTN BLACK AUX_COM WHITE +24/12 VDC RED V+ (12 OR 24 VDC NOM) SENSOR/TRIP EN ORANGE AUX_NO WHITE SENSOR_OUT BROWN BLUE Rx Rx DISABLE/DELAY PURPLE YELLOW Rx CONNECT Rxx VALUE PER TRIP FUNCTION/TRIP DELAY GRAPH TO SET TRIP LEVEL N/C Cx 7 ms/µF GND V(I) V(I) = ±I (.0030) + 2.50 CONNECT ORANGE TO V+ FOR SENSINGSENSING ACTIVE ONLY WITH LOW SIDE DRIVE ENABLED AS SHOWN SENSOR INPUT SINK 15 mA MAX GND LEAVE PURPLE NC FOR TRIP ENABLE GROUND FOR TRIP DISABLE CONNECT Cx FOR TRIP DELAY, 7 ms/µF GND KCS03X012/KCS03X024 ENERGIZE/CLOSE CONTACTS USING SWITCH OR SOLID STATE DEVICE-HIGH SIDE DRIVE SHOWN RTN BLACK +24/12 VDC RED V+ (12 OR 24 VDC NOM) SENSOR/TRIP EN ORANGE AUX_NO WHITE SENSOR_OUT BROWN V(I) V(I) = ±I (.0030) + 2.50 CONNECT ORANGE TO V+ FOR SENSINGSENSING ACTIVE WITH/WITHOUT HIGH SIDE DRIVE ENABLED AS SHOWN SENSOR INPT SINK 15 mA MAX BLUE Rx DISABLE/DELAY PURPLE N/C Cxx AUX_COM WHITE Rxx YELLOW Rx CONNECT Rxx VALUE PER TRIP FUNCTION/TRIP DELAY GRAPH TO SET TRIP LEVEL GND 7 ms/µF GND LEAVE PURPLE NC FOR TRIP ENABLE GROUND FOR TRIP DISABLE CONNECT Cxx FOR TRIP DELAY, 7 ms/µF AEROSPACE, DEFENSE & MARINE /// KCS03 CURRENT SENSING CONTACTOR PAGE 7 LET’S CONNECT We make it easy to connect with our experts and are ready to provide all the support you need. Just call your local support number or visit www.te.com/industrial to chat with a Product Information Specialist. Technical Support te.com/support-center North America +1 800 522 6752 Asia Pacific +86 400 820 6015 North America (Toll) +1 717 986 7777 Japan +81 044 844 8180 EMEA/South Africa +800 0440 5100 Australia +61 2 9554 2695 EMEA (Toll) +31 73 624 6999 New Zealand +64 (0) 9 634 4580 India (Toll-Free) +800 440 5100 te.com/kcs03 AMP, AGASTAT, CII, DEUTSCH, HARTMAN, KILOVAC, LL ROWE, MICRODOT, NANONICS, POLAMCO, Raychem, SEACON, TE, TE Connectivity and the TE connectivity (logo) are trademarks of the TE Connectivity Ltd. family of companies. Other products, logos, and company names mentioned herein may be trademarks of their respective owners. While TE Connectivity (TE) has made every reasonable effort to ensure the accuracy of the information herein, nothing herein constitutes any guarantee that such information is error-free, or any other representation, warranty or guarantee that the information is accurate, correct, reliable or current. The TE entity issuing this publication reserves the right to make any adjustments to the information contained herein at any time without notice. All implied warranties regarding the information contained herein, including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose are expressly disclaimed. The dimensions herein are for reference purposes only and are subject to change without notice. Specifications are subject to change without notice. Consult TE for the latest dimensions and design specifications. © 2016 TE Connectivity Ltd. family of companies All Rights Reserved. 0-0000000-0  12/16    AEROSPACE, DEFENSE & MARINE /// KCS03 CURRENT SENSING CONTACTOR