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engineering data sheet series kca relay - nonlatch - ac coil 3 pdt, 25 amp application notes: 102 007 applicable socket: so-1062-8917 so-1057-8912 (d-mount) all welded construction contact arrangement 3 pdt designed to the performance standards of mil-prf-6106 principle technical characteristics contacts rated at low level, 28 vdc; 115 vac, 400 hz, 1? and 115/200 vac, 400 hz, 3? weight 0.188lb max dimensions 1.01in x 1.01in x 1.00in hermetically sealed, corrosion resistant metal can. detail specifications and ordering data appear on the following pages. contact electrical characteristics contact rating per pole and load type [1] load current in amps @28 vdc @115 vac 400 hz @115/200 vac 400 hz, 3? @115/200 vac 60 hz, 3? [7] @230/400 vac 400 hz, 3? [8] resistive [3] inductive [2] motor lamp overload rupture 25 12 10 5 50 60 25 15 10 5 80 100 25 15 10 5 80 100 2.5 2.5 2 1 n/a n/a 5 5 2 2 n/a n/a featuring leach ? power and control solutions www.esterline.com americas 6900 orangethorpe ave. p.o. box 5032 buena park, ca 90622 . . tel: (01) 714-736-7599 fax: (01) 714-670-1145 europe 2 rue goethe 57430 sarralbe france . . tel: (33) 3 87 97 31 01 fax: (33) 3 87 97 96 86 asia units 602-603 6/f lakeside 1 no.8 science park west avenue phase two, hong kong science park pak shek kok, tai po, n.t. hong kong tel: (852) 2 191 3830 fax: (852) 2 389 5803 data sheets are for initial product selection and comparison. contact esterline power systems prior to choosing a component. date of issue: 07/10 - 154 - page 1 of 4
coil characteristics series kca vac 400 hz vac 50 thru 400 hz vac 400 hz code e f j k t nominal operating voltage 28 115 28 115 230 maximum operating voltage 30 122 30 122 248 maximum pickup voltage - cold coil at +125 c 22 90 23 95 180 - during high temp test at +125 c 24.4 95.4 24.6 100 185 - during continuous current test at +125 c 25.6 103.5 25.9 105 195 maximum drop-out voltage 10 30 10 30 60 coil current maximum milliamperes at +25 c 225 40 120 28 22 general characteristics temperature range -70c to +125c minimum operating cycles (life) at rated load 50,000 [2] minimum operating cycles (life) at 25% rated load 200,000 dielectric strength at sea level - all circuits to ground and circuit to circuit 1250 vrms - coil to ground 1000 vrms dielectric strength at altitude 80,000 ft 500 vrms [4] insulation resistance - initial (500 vdc) 100 m w min - after environmental tests (500 vdc) 50 m w min sinusoidal vibration (a, d, e and w mounting) 0.12da / 10 to 70 hz 30g / 70 to 3000 hz sinusoidal vibration (j mounting) 0.12da / 10 to 57 hz 20g /57 to 3000 hz random vibration - applicable specification mil-std-202 - method 214 - test condition - a, d and e mounting 1g (0.4g 2 /hz, 50 to 2000 hz) - test condition - g and j mounting 1e (0.2g 2 /hz, 50 to 2000 hz) - duration 15 minutes each plane shock (a, d, e and w mounting) 200g / 6 ms shock (g and j mounting) 100g / 6 ms maximum contact opening time under vibration and shock 10 s operate time at nominal voltage@25c 20 ms max release time at nominal voltage@25c 50 ms max contact make bounce at nominal voltage@25c 1 ms max contact release break bounce at nominal voltage@25c 0.1 ms max weight maximum 0.188lb unless otherwise noted, the specified temperature range applies to all relay characteristics. date of issue: 0710 - 155 - page 2 of 4
notes series kca [1] standard intermediate current test applicable. [2] dc inductive load 10,000 cycles, ac inductive load 20,000 cycles. [3] for full rated load, max. temp. and altitude use no. 12 wire or larger. relays to be mounted to limit mounting bracket temp. to 135 c. [4] 500 vrms with silicone gasket compressed, 350 vrms all other conditions. 5. reference military specification: mil-prf-6106 and ms27743. 6. special models available upon request. [7] 60 hz load life 10,000 cycles. [8] temperature range: non-operating -62 c to +95 c operating -54 c to +71 c 9. time current relay characteristics per mil-prf-6106. numbering system kca- a 4 f basic series designation__________________________| | | | 1-mounting style (a,d,e,j,w)__________________________| | | 2-terminal types (1,2,4) [1]______________________________| | 3-coil voltage see coil characteristics (e,f,j,k or t)________| mounting styles date of issue: 07/10 - 156 - page 3 of 4
terminal types series kca coil polarity not applicable std. tol: .xx .03; .xxx .010 d a t e o f i s s u e : 07 /10 - 1 6 1 - p a g e 4 o f 4 t e r m i n a l t y p e 1 + - - + f i n i s h : c a s e - p a i n t e d l e a c h b l u e t e r m i n a l s - t i n / l e a d . 0 9 3 . 0 0 3 d i a 9 p l a c e s . 2 7 0 9 p l a c e s . 2 5 0 2 p l a c e s . 0 6 2 . 0 0 2 d i a 2 p l a c e s c a s e - p a i n t e d l e a c h b l u e t e r m i n a l t y p e 2 t e r m i n a l s - t i n / l e a d f i n i s h : 2 p l a c e s . 3 0 0 . 0 2 0 2 p l a c e s . 0 4 0 . 0 0 2 d i a + - - + 9 p l a c e s 6 p l a c e s . 3 7 5 . 0 2 0 . 0 9 3 . 0 0 3 d i a - + - + 3 p l a c e s . 6 2 5 . 0 2 0 + - t e r m i n a l t y p e 4 f i n i s h : c a s e - p a i n t e d l e a c h b l u e p i n s - g o l d p l a t e d - + + - . 0 9 3 d i a + . 0 0 2 - . 0 0 1 9 p l a c e s . 2 7 0 9 p l a c e s . 0 5 0 . 0 0 5 . 0 6 2 . 0 0 1 d i a 2 p l a c e s . 2 5 0 2 p l a c e s s i l i c o n r u b b e r g a s k e t b 3 b 1 c 3 c 1 x 1 x 2 c 2 b 2 s c h e m a t i c d i a g r a m a 2 a 1 a 3 s t a n d a r d t e r m i n a l l a y o u t c o n t r a s t i n g b e a d . 4 5 0 . 6 0 0 . 3 0 0 . 1 5 0 . 6 3 0 . 4 3 2 . 2 3 4 x 1 x 2 a b 3 2 1 c w i r i n g d i a g r a m c o n t r a s t i n g b e a d a 1 b 1 x 1 c 1 x 2 a 2 b 2 a 3 b 3 c 2 c 3
application notes n102 relays and temperature variations most relay parameters are specified as maximum values over the rated temperature range of the specific relay. users often find that key parameters differ significantly at ambient temperature (20-25c) and sometimes fall into the trap of specifying their system around these ambient parameters. additionally the actual temperature experienced by the relay can be far in excess of existing ambient temperatures due to the heat generated by the coil current and the contact load. figure 1 is the summary of temperature effects on relay electrical characteristics. temperature resistance current operating voltage release voltage operate time release time increase up down up up up up decrease down up down down down down fig. 1 the following formulas are sometimes useful in calculating the effects shown above. 1. change in coil resistance due to change of ambient temperature can be calculated by the following formula. r = r 20 [1 + .0039 (t-20)] where: r = coil resistance at given temperature r 20 = coil resistance at 20c t = c ambient temperature "rule of thumb" : for each 10c change of temperature, coil resistance will change approximately 4%. 2. high and low temperature pick up voltage: e 2 = e 1 k 2, where: e 2 = pick up voltage at t 2 temperature e 1 = pick up voltage at 20c k 2 = coefficient of correction found on the graph in fig. 2 at t 2 date of issue: 6/00 - 15 - page 1 of 2
3. calculation of coil temperature rise when r initial and r final are known: delta t = (234.5 + t 1 ) (r 2 /r 1 - 1) delta t = temperature rise (c) t 1 = initial temperature (c) r 1 = initial resistance (ohms) r 2 = final resistance (ohms) r 2 = k 2 r 1 temperature can also be found by making the r 2 /r 1 ratio = the coefficient of correction graph in fig. 2, and then finding the corresponding temperature. temperature correction chart for resistance fig. 2 example: catalog indicates coil resistance of 290 ohm at 25c. what is the value at 125c? from the chart: 290 x 1.39 = 403.31 ohms. date of issue: 6/00 - 16 - page 2 of 2
application notes n007 suppressor devices for relay coils the inductive nature of relay coils allows them to create magnetic forces which are converted to mechanical movements to operate contact systems. when voltage is applied to a coil, the resulting current generates a magnetic flux, creating mechanical work. upon deenergizing the coil, the collapasing magnetic field induces a reverse voltage (also known as back emf) which tends to maintain current flow in the coil. the induced voltage level mainly depends on the duration of the deenergization. the faster the switch-off, the higher the induced voltage. all coil suppression networks are based on a reduction of speed of current decay. this reduction may also slow down the opening of contacts, adversly effecting contact life and reliability. therefore, it is very important to have a clear understanding of these phenomena when designing a coil suppression circuitry. typical coil characteristics on the graph below, the upper record shows the contacts state. (high level no contacts closed, low level nc contacts closed, intermediate state contact transfer). the lower record shows the voltage across the coil when the current is switched off by another relay contact. the surge voltage is limited to -300v by the arc generated across contact poles. discharge duration is about 200 mircoseconds after which the current change does not generate sufficient voltage. the voltage decreases to the point where the contacts start to move, at this time, the voltage increases due to the energy contained in the no contact springs. the voltage decreases again during transfer, and increases once more when the magnetic circuit is closed on permanent magnet. operating times are as follows: time to start the movement 1.5ms total motion time 2.3ms transfer time 1.4ms contact state date of issue: 6/00 - 8 - page 1 of 4
types of suppressors: passive devices. the resistor capacitor circuit it eliminates the power dissipation problem, as well as fast voltage rises. with a proper match between coil and resistor, approximate capacitance value can be calculated from: c = 0.02xt/r, where t = operating time in milliseconds r = coil resistance in kiloohms c = capacitance in microfarads the series resistor must be between 0.5 and 1 times the coil resistance. special consideration must be taken for the capacitor inrush current in the case of a low resistance coil. the record shown opposite is performed on the same relay as above. the operation time becomes: - time to start the movement 2.3ms - transfer time 1.2ms the major difficulty comes from the capacitor volume. in our example of a relay with a 290 w coil and time delay of 8 ms, a capacitance value of c=0.5 uf is found. this non polarized capacitor, with a voltage of 63v minimum, has a volume of about 1cm 3 . for 150v, this volume becomes 1.5 cm 3 . date of issue: 6/00 - 9 - page 2 of 4
the bifilar coil the principle is to wind on the magnetic circuit of the main coil a second coil shorted on itself. by a proper adaptation of the internal resistance of this second coil it is possible to find an acceptable equilibrium between surge voltage and reduction of the opening speed. to be efficient at fast voltage changes, the coupling of two coils must be perfect. this implies embedded windings. the volume occupied by the second coil reduces the efficiency of the main coil and results in higher coil power consumption. this method cannot be applied efficiently to products not specifically designed for this purpose. the resistor (parallel with the coil) for efficient action, the resistor must be of the same order of magnitude as the coil resistance. a resistor 1.5 times the coil resistance will limit the surge to 1.5 times the supply voltage. release time and opening speed are moderately affected. the major problem is the extra power dissipated. semi-conductor devices the diode it is the most simple method to totally suppress the surge voltage. it has the major disadvantage of the higher reduction of contact opening speed. this is due to the total recycling, through the diode, of the energy contained in the coil itself. the following measurement is performed once again on the same relay. operation times are given by the upper curve: - time to start the movement 14ms - transfer time 5ms these times are multiplied by a coefficient from 4 to 8. the lower curve shows the coil current. the increase prior to no contact opening indicates that the contact spring dissipates its energy. at the opening time the current becomes constant as a result of practically zero opening speed. due to this kind of behavior, this type of suppression must be avoided for power relays. for small relays which have to switch low currents of less than 0.2 a, degradation of life is not that significant and the method may be acceptable. date of issue: 6/00 - 10 - page 3 of 4
the diode + resistor network it eliminates the inconvenience of the resistor alone, explained above, and it limits the action of a single diode. it is now preferred to used the diode + zener network. the diode + zener network like the resistor, the zener allows a faster decurrent decay. in addition it introduces a threshold level for current conduction which avoids the recycling of energy released during contact movement. the lower curve on the opposite record demonstrates those characteristics. voltage limitation occurs at 42v. the two voltages spikes generated by internal movement are at lower levels than zener conduction. as a result, no current is recycled in the coil. the opening time phases are as follows: - time to start the movement 2.6ms - total motion time 2.4ms - transfer time 1.4ms the release time is slightly increased. the contacts' opening speed remains unchanged. date of issue: 6/00 - 11 - page 4 of 4
engineering data sheet so-1062-8917 relay socket 25 amp basic socket series designation for: series kca meets the requirements of: mil-dtl-12883 general characteristics 1. supplied with mounting hardware and no. 12 contacts, no. 12 crimp for power terminals; no. 16 contacts, no. 16 crimp for coil terminals. 2. standard tolerances .xx .01; xxx .005 3. weight .118 lb. max 4. temperature range -70 c to +125 c featuring leach ? power and control solutions www.esterline.com americas 6900 orangethorpe ave. p.o. box 5032 buena park, ca 90622 . . tel: (01) 714-736-7599 fax: (01) 714-670-1145 europe 2 rue goethe 57430 sarralbe france . . tel: (33) 3 87 97 31 01 fax: (33) 3 87 97 96 86 asia units 602-603 6/f lakeside 1 no.8 science park west avenue phase two, hong kong science park pak shek kok, tai po, n.t. hong kong tel: (852) 2 191 3830 fax: (852) 2 389 5803 data sheets are for initial product selection and comparison. contact esterline power systems prior to choosing a component. date of issue: 8/09 - 20 - page 1 of 1
engineering data sheet so-1057-8912 relay socket 25 amp basic socket series designation for: series kc meets the requirements of: mil-dtl-12883 general characteristics 1. supplied with mounting hardware no. 12 contacts, no. 12 crimp for power terminals; no. 16 contacts, no. 16 crimp for coil terminals. 2. standard tolerances .xx .01; xxx .005 3. weight .112 lb. max 4. temperature range -70 c to +125 c featuring leach ? power and control solutions www.esterline.com americas 6900 orangethorpe ave. p.o. box 5032 buena park, ca 90622 . . tel: (01) 714-736-7599 fax: (01) 714-670-1145 europe 2 rue goethe 57430 sarralbe france . . tel: (33) 3 87 97 31 01 fax: (33) 3 87 97 96 86 asia units 602-603 6/f lakeside 1 no.8 science park west avenue phase two, hong kong science park pak shek kok, tai po, n.t. hong kong tel: (852) 2 191 3830 fax: (852) 2 389 5803 data sheets are for initial product selection and comparison. contact esterline power systems prior to choosing a component. date of issue: 8/09 - 15 - page 1 of 1

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