RELAY INTERFACE

MODULE:-
1 Introduction:-
Now days Clear and reliable potential separation is becoming more and more important for
the reliability of industrial automation facilities. Modern relay or optocoupler
interfaces fulfill the most varied tasks. Whether in production engineering, for the
electrical equipping of machines or in control engineering for power distribution,
building automation and materials processing - the main aim is to guarantee the
exchange of signals between the process peripherals and the higher level control systems. This
exchange must provide reliable operation, be floating and electrically unambiguous

Relay interface Module a hardware device used for remote device Switching. It is nothing
but single or combination of multiple relay’s mounted on PCB either direct soldered or mount
using relay Socket (in this case relay socket solder on PCB & relay clip in socket & use relay clip
for Relay tight fitting which help working relay module to under vibration condition)

Relay interface modules must have the following characteristics:

• Coupling of different signal levels
• Reliable electrical isolation between input and output
• Ease of operation.
• Easy mounting arrangement
• Independence of the type of switching current (AC and DC)

1 Application:-
Relay module used as Interfacing PLC (pro / Drive / DCS Digital
Outputs to field or field devices. These will be in isolation between
the I/P & O/P (Output are galvanically isolated through Relays).The
relay module can be used to sense external ON/OFF conditions and
to control a variety of external devices. So relay module used as

• Interfacing of PLC I/Os to field Sensors & actuators

• Multiplication of PLC O/Ps for separately driving actuators,
annunciators & other devices.
• Isolation of high voltage load & input devices from sensitive
PLC electronics.
• Providing channel wise isolation for PLC inputs & outputs.

RELAY INTERFACE MODULE 1

 RELAY INTERFACE
1 MODULE:-
Construction:-

Relay module is Customized product & manufacture according to the requirement so it is

not easy to differentiate in number of types. But for simplicity relay module differentiate on which
type relay is used, number of relay used in the module and choice of features such as with /
without fuse and with / without relay mounting base.

Circuit & Mounting Arrangement

Fig 3.1.1 Schematic Circuit & Mounting diagram for 8 channel 2 changeover relay module w/o
fuse

Following components are used in module

1) PCB
2) Relay
○ Electromechanical Relay
○ Solid State Relay
3) Relay mounting Socket ( if
require)
4) I / O terminal
5) LED for indication
6) Freewheeling Diode
7) Mounting arrangement
8) Extra Feature components
○ Fuse Socket & fuse, Fuse
fail Indication circuitry
○ Surge protection

RELAY INTERFACE MODULE 2

 RELAY INTERFACE
MODULE:-
1.1 PCB
A printed circuit board, or PCB, is used to mechanically support and electrically
connect the relay & I/O terminal using conductive pathways, tracks,
or traces, etched from copper sheets laminated onto a non-conductive substrate. It is
also referred to as printed wiring board (PWB) or etched wiring board. The size
of PCB depends upon the requirement & Number of used in module. Generally Single
side or Double side Board is use in Relay module for more detail please click hear
PCB

Leading Manufacturer:-

1.2 Relay
Normally all PCB mounting type of relays are suitable for using in
Relay module. The Selection of relay is depending upon the
Application & Requirement. Relay either directly soldered on PCB or
mount on Relay socket.

Relay interface modules are manufacture in different channel

density viz 1, 2, 4, 6, 8, 16 & 32 channels. (Also manufacture different number of
channel relay module depending upon the Requirement)
Number of o/p contact following number of change over Relay Interface module is
available
1) One Change over Relay Interface module
2) Two Change over Relay Interface module
3) Four Change over Relay Interface module
4) Six Change over Relay Interface module
5) Only NO or NC contact type Relay Interface module

1.1 Relay Socket (if required)

On module Relay either directly soldered on PCB or mount on Relay socket. In direct
soldering method relay permanently soldered on PCB. In
this type there is no possibility for loose connection under
any condition (unless & until relay
burnt down or mechanically
damaged).even though it is
economical way to built the relay
module but in this method if relay
burnt or damaged there is no
scope for relay replacement hence not suitable. To easily
maintenance Relay socket is used for mounting the relay on
PCB. For tight & normal contact Relay clip is used.

RELAY INTERFACE MODULE 3

 RELAY INTERFACE
1.2 MODULE:-
I/O Terminal

A terminal is the point at which a conductor from an

electrical device or network comes to an end and
provides a point of connection to PCB.

PCB mounted Screw or spring type Terminal used in relay module. To reduce the
relay module size often double Dekker type terminal is used. The
selection of terminal is depend on the contact rating

1.3 Flyback /Freewheeling Diode

A flyback diode (sometimes called

a snubber diode, freewheeling diode, suppressor diode,
or catch diode[) is a diode used to eliminate flyback,
the sudden voltage spike seen across
an inductive load when its supply voltage is suddenly
reduced or removed.

Fly back /Freewheeling Diode used across the relay

1.4 LED for Indication

LED is use for indication purpose. The selection of LED is
important as it indicate which relay is operating/energies.
Depending on Application either center glow or Diffused
type of LED is used. Normally green Led is use for Relay On
indication purpose. RED color LED use for power on & Fuse
fails indication.

Coil

1.5 Mounting arrangement

Mounting of module want to permanently fix in
systems then screw mounting use (normally
now days no one use this
Type mounting).
Otherwise din rail
mounting is preferred

RELAY INTERFACE MODULE 4

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MODULE:-

1.6 Extra Feature components

1.6.1 Fuse Protection

For protection from Short circuit, overload the Fuse is placed on relay contact
side

Normally Glass fuse is used in Relay module. Depending upon the

requirement or relay module size the Horizontal mounting or vertical
mounting fuse socket is used to mount the Fuse. Some time resettable
fuse is used. Red Led is used to fuse fail indication Purpose

1.6.2 Surge Protection

 Varister
A varistor is an electronic component with a significant non-ohmic current–
voltage characteristic. Varistors are used to protect circuits against excessive
transient voltages by incorporating them into the circuit in such a way that, when
triggered, they will shunt the current created by the high voltage away from the
sensitive components. A varistor is also known as Voltage Dependent
Resistor or VDR. A varistor’s function is to conduct significantly increased current
when voltage is excessive.
A varistor remains non-conductive as a shunt mode device during normal
operation when voltage remains well below its "clamping voltage". If
a transient pulse (often measured in joules) is too high, the device may melt, burn,
vaporize, or otherwise be damaged or destroyed.
 Snubber circuit
Snubbers are used in electrical systems with
an inductive load where the sudden interruption
of current flow often leads to a sharp rise in
voltage across the device creating the
interruption. This sharp rise in voltage is a transient and can damage and lead to
failure of the controlling device. A spark is likely to be generated (arcing), which can
cause electromagnetic interference in other circuits. The snubber prevents this
undesired voltage by conducting transient current around the
device

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 RELAY INTERFACE
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RC snubbers

A simple snubber comprising a small resistor (R) in series with a

small capacitor (C) is used. Snubbers are used to prevent arcing across the contacts
of relays and switches and the electrical interference and welding/sticking of the
contacts that can occur. An appropriately-designed RC snubber can be used with
either DC or AC loads. This sort of snubber is commonly used with inductive loads
such as electric motors. The voltage across a capacitor cannot change
instantaneously, so a decreasing transient current will flow through it for a small
fraction of a second, allowing the voltage across the switch to increase more slowly
when the switch is opened. While the values can be optimized for the application, a
100 ohm non-inductive resistor in series with a 100 nanofarad, or larger, capacitor
of appropriate voltage rating is usually effective. Determination of voltage rating can
be difficult owing to the nature of transient waveforms; the actual rating can be
determined only by measuring temperature rise of the capacitor.

1 Types of relay module

On Types of Relay we can Differentiate Relay Interface module as Per Below
1) Electromechanical Type Relay Module
2) Solid State Relay Type Relay Module
3) Customized (hybrid) Relay Module

1.1 Electromechanical Relay Interface module

Electromechanical relay Interface module is use in lower current switching application. Due
possibility of spark at the time of relay switching hence it is not used in explosive
environment.

Advantage
• Economical
• Easily available in Local market
Disadvantage
• Not suitable for high Switching frequency application
• Not suitable for high current application
• Restriction due to contact life
• Sometime contact chatter
RELAY INTERFACE MODULE 6
 RELAY INTERFACE
• NotM ODULE
suitable :- environments where a
in explosive
Spark must not be generated during turn-on

1.1 Solid State Relay Module

Solid State Relay Modules deliver electrically clean, Opto isolated, noise free Output. These
Modules available are for various voltage and performance levels. They are used as interface
modules for matching process peripherals to control, signaling and regulation devices. SSR Type
Module is used when the interface between the process peripherals and electronics is subject to
the following requirements:
• Low control power
• High switching frequencies
• No contact chatter
• Resistance to vibrations and polluted environments
• Long service life, independent of the number of switching operations
• explosive environments

Advantages
• Ideal for high Switching frequency application
• Ideal for high current application
• Long life as no moving or mechanical part
• Can be used in explosive environments where a
Spark must not be generated during turn-on
• Clean, bounceless operation
•
Disadvantages
• costly
• Not Easily available in Local market
• Not suitable for some application due to SSR leakage current

1.1 Customized (hybrid) Relay Module

As name suggests this Relay module is nothing but combination of
SSR & Electromechanical relay as per requirement & application in Single board.

RELAY INTERFACE MODULE 7