Optimized Title: TE Connectivity Kilovac EV200AAANA Relay Contactor (TYCO) 12-24V 900V 500A

KOEED · DC Contactors · High-Voltage Relay · In stock

What Is the TE Connectivity EV200AAANA Kilovac Relay Contactor?

The EV200AAANA is a hermetically sealed, single-pole DC contactor from the TE Connectivity Kilovac product line, rated to switch and carry DC loads up to 900 volts and 500 amps continuously. Internally, the contactor houses a set of vacuum-sealed contacts that are opened and closed by a 12-24V DC electromagnetic coil fitted with an integrated economizer circuit. This particular variant — the AAANA suffix — designates a bottom-mount stud configuration with no auxiliary contact, making it the most widely deployed EV200 sub-model across electric vehicle battery packs, DC fast-charging infrastructure, stationary energy storage systems, and industrial DC bus disconnects. Originally developed under the TYCO Electronics brand before the Kilovac acquisition, the EV200 series has become the de facto standard sealed DC contactor for systems operating above 400V.

In short: The EV200AAANA is the industry-standard sealed DC contactor for high-voltage applications — rated 900V / 500A, controlled by a 12-24V coil, and found inside EV battery packs, solar inverters, and DC industrial power systems worldwide.

Key Hardware Details

1. Hermetically Sealed Contact Chamber

What it means: The main power contacts operate inside a permanently sealed envelope backfilled with an inert gas — typically nitrogen or a hydrogen-nitrogen mixture. There is no vent to atmosphere and no arc chute exposed to the outside environment.
Why it matters: In a DC circuit, opening under load draws a sustained arc that does not self-extinguish at zero-crossing the way AC does. The sealed gas environment quenches this DC arc far more effectively than open-air contacts could, while also preventing oxidation, dust ingress, and humidity-related contact degradation over thousands of cycles.
Result: Consistent low contact resistance throughout the contactor's service life, even in harsh environments like unpressurized EV battery compartments, marine DC systems, and outdoor solar combiner boxes.

2. Integrated Coil Economizer

What it means: The EV200AAANA coil circuit includes a built-in PWM controller that delivers a short high-current pulse to pull in the contacts and then reduces the holding current to roughly one-tenth of the pull-in value once the armature is seated.
Why it matters: Without an economizer, a DC contactor coil would continuously dissipate full pull-in power — often 10 to 15 watts — generating substantial waste heat inside a sealed battery enclosure. The economizer cuts steady-state coil power to approximately 1.5 to 3 watts, dramatically reducing thermal load and extending coil life.
Result: The contactor can remain energized for hours without overheating, which is essential for EV drive cycles where the main contactor stays closed for the entire trip.

3. Bidirectional Switching Capability

What it means: The main power studs are not polarity-sensitive for current flow — the contactor can interrupt DC current flowing in either direction through its contacts.
Why it matters: In a battery system, current flows in one direction during discharge (battery to load) and the opposite direction during regen or charging (charger to battery). A unidirectional contactor would require a second unit in anti-parallel, doubling cost and enclosure footprint.
Result: A single EV200AAANA can serve as the main battery disconnect in systems that both charge and discharge through the same DC bus — EVs, hybrid energy storage, and bidirectional inverter systems.

4. Stud-Type Power Terminals

What it means: The main current path terminates in threaded copper studs (typically M8 or M10) that protrude from the top of the contactor body, designed to accept ring terminals secured with nuts and lock washers.
Why it matters: At 500A continuous, contact resistance at the termination is critical — a loose or corroded bolted joint generates I-squared-R heating that can melt insulation or ignite adjacent materials. Stud terminals allow torque-controlled fastening to the manufacturer's specified value, something quick-connect or plug-in terminals cannot guarantee at these current levels.
Result: Reliable, low-resistance power connections that can be torqued to specification and inspected visually during routine maintenance.

Key Specifications

Always verify exact ratings, coil polarity, and mounting dimensions from the Kilovac EV200 datasheet or product label before integration. For application-specific derating curves (make/break current vs. voltage, thermal limits at altitude, short-circuit withstand), consult the official TE Connectivity EV200 product specification.

Where the EV200AAANA Is Deployed

• Electric vehicle traction battery packs: Serves as the main positive and negative contactors that connect the high-voltage battery to the inverter and DC-DC converter. The EV200 is found in early Tesla Roadster packs, commercial EV conversions, electric buses, and medium-duty electric truck platforms.
• DC fast-charging stations: Isolates the charging cable from the power electronics until the vehicle handshake is complete and the isolation monitor confirms a safe connection.
• Stationary energy storage (BESS): Used as the DC-side disconnect between battery racks and the central inverter in utility-scale and commercial behind-the-meter storage installations, where the 500A rating allows paralleling fewer contactors per rack.
• Solar combiner and inverter DC inputs: Provides a remotely controllable DC disconnect between the PV array and the inverter input stage, enabling rapid shutdown compliance and arc-fault circuit isolation.
• Marine and submarine DC distribution: The sealed construction makes the EV200 suitable for unpressurized compartments where salt spray and humidity would rapidly corrode open-frame contactors.
• Industrial DC motor drives: Disconnects large DC motors (cranes, hoists, extruders) from their DC supply during emergency stop or lockout-tagout procedures.

Frequently Asked Questions

"What is the difference between the EV200AAANA and the EV200HAANA?"

Both are 900V / 500A sealed DC contactors in the Kilovac EV200 family, but the key difference is in the coil circuit. The AAANA variant uses an internal coil economizer that accepts a continuous 12-24V DC supply and self-regulates the holding current. Some HAANA variants (depending on production era) may require an external economizer or use a different coil configuration. From a mounting and power-terminal perspective, they are mechanically interchangeable — same stud pattern, same busbar footprint. Always verify the coil label on the contactor body: it will state the nominal coil voltage and whether an external economizer is required. If your system was designed around the AAANA, stick with the AAANA to avoid coil-drive compatibility issues.

"Do I need a precharge circuit when using this contactor?"

In almost all DC applications above 100V, yes — a precharge circuit is strongly recommended. When the EV200AAANA closes directly onto a capacitive load (such as the DC-link capacitors inside an inverter), the inrush current can briefly exceed several thousand amps, which may weld the contacts or degrade them prematurely. A proper precharge sequence closes a smaller relay through a current-limiting resistor first, allowing the capacitor bank to charge to near the battery voltage before the main EV200 contactor closes. The contactor is then only closing across a small differential voltage, well within its rated make capability. If you are designing a battery disconnect system, budget for a precharge contactor, a precharge resistor (typically 25-100 ohms, rated for the pulse energy), and a control sequence that enforces the precharge-then-close timing.

"How do I verify this is a genuine TE Connectivity Kilovac part and not a counterfeit?"

Genuine EV200 contactors have a stamped metal body with laser-etched markings that include the TE logo, the full part number (EV200AAANA), a date code, and the coil voltage rating. The manufacturing quality is evident in the hermetic weld seam around the body, the consistent thread quality on the power studs, and the molded coil connector housing. Counterfeit units often show inconsistencies in the label font, poorly machined stud threads, or an unusually light weight. All products sold through koeed.com are sourced through authorized channels. If you need to verify a specific unit, send us the date code and we can trace its origin.

"Can I use this contactor to switch an AC load?"

While the EV200 series is physically capable of switching AC, it is specifically optimized for DC interruption. The sealed gas fill and contact geometry are designed around the DC arc behavior — there is no zero-crossing to assist with arc extinction. For pure AC applications, a conventional open-frame AC contactor rated for the appropriate AC voltage class (e.g., IEC 60947-4-1) will typically be less expensive and equally reliable. The EV200AAANA's value proposition is specifically in the DC domain, where its sealed construction and gas-quenched arc chamber solve a problem that open-air contactors cannot handle at high DC voltages.

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