Relay Basics PDF

Schematic Application Sketch
- Electrical controlled switch

- Controlling of heavy load with low control energy
- Galvanic separation between control and load circuit
General Purpose Relays EMEA
Relay_Basics0900 Page 2
Technical Requirements
Purpose
Aspects
Realised by
The main function...
Control of
electrical energy
Contact number
and dimensions
Contacts
The need...
Amotor to
operate with the
control signal
Voltage
DC / AC
Coil
The consequence...
Separation of
control and load
Protection class
creepage/clearence
Insulation
The interface...
Electrical
connection
PCB, Plug in
Pin
configuration
The conditions...
Adaptation to
surrounding
Space, packing,
Dimensions
ambient temperature
Block Diagram
Primary Side
Secondary Side
Input
Control:
Coil voltage
Relay
coil
Intermediate signal:
Magnetic circuit
Contacts
Galvanic
separation
Output
Contact
switching
voltage/current
Application Areas
Electromechanical Relays
Telecom
Automotive
General Purpose
Current:
low
high
low to high
Voltage:
low
low
low to high
Coil:
DC
DC
DC or AC
Insulation:
low
low
high
Load:
well defined
well defined
huge range of different loads
tough
able to switch mains voltage
High lights: small

Load range:
5V DC ... 300V DC
5V AC ... 230 / 400V AC
0.1A ... 30A
10
10
Contactors
General Purpose Relays:
Voltage [V]
Typical Application Area
General Purpose
Relays
10
1
Signal
Relays
10
-1
10
-2
10
-1
10
10
Switching Current [A]
Principal Designs
Method of connection:
PCB
Plug in (need a socket) or

PCB
Magnetic Systems - Coils
DC-systems
monostable
AC-systems
bistable
DC - Relay Systems
Monostable Relays
Bistable Relays
one coil
operated UA1-A2 = Uin
released UA1-A2 = 0V
low power consumption 0.2 0.7W
one or two coils

SET:
UA2 (-) / A3 (+)
RESET: UA1(-) / A3 (+)

Hold by permanent magnet or remanent core
DC - Bistable Relay Systems

Bistable Polarized Relays
Bistable Remanent Relays
one or two coils
one or two coils

SET:
UA2 (-) / A3 (+)
SET:
UA2 / A3 (+-/-+)
RESET: UA1(-) / A3 (+)
RESET: UA1 / A3 (-+/+-)
low power consumption approx.0.4W
high power consumption 1.2W
UCoil [Volt]
Operating Voltages -Terms
UMAX
UNominal
UPull-in
UNon-operate
Relay On state
Relay in a not specified state
UHold
URelease
Relay OFF state

Voltage range depends
200%
Coil voltage [ % of V
on ambient temperature
nom inal
Coil Operating Range
O perating range
V ma x
100%
V o p era te E=V
nom
E=0
V ho ld
V releas e
Drop-out range
0%
-40
-20
+20
+40
+60
+80
Am bien t tem peratu re [ C ]

Electrical Contact, Designation

Contact
Number
Single Pole
Designation
Make Contact
Normally Open Contact (N/O)
Schlieer
Break Contact
Normally Closed Contact (N/C)
ffner
Changeover Contact
(C/O)
Double Throw
Wechsler
Double Make
Brckenschlieer
(D/M)
Make Contact
Normally Open Contact (2N/O)
Double Pole Schlieer
All other configuration like
1pole possible
GB
USA
SPST-NO
SP
21
C/O or
SPDT
SPST-NO
DM
2A
2SPST-NO
Symbol
Influences on Electrical Contact
Influences
electrical
Parameters
z current
z voltage
thermal
z arc
mechanical z friction
z pressure
ambient
z dust
conditions z gases
chemical
z oxidation
Effect
heating, melting, material migration, chemical
reactions, fritting, electrical discharge, contact
resistance
melting of contact material, material migration
deformation, wear, cold welding, contact resistance
increased wear, particles, formation of chemical
layers an corrosion
contact resistance, inorganic and organic layers,
corrosion
Influences on Switching Contact

Depending on Load Range
Load range
Main influences Contact material
dry circuit
zmechanical
zgold plated
<100mV, <10mA zchemical
materials
lowlevel switching
<1V, <10mA
zAgNi 0.15
intermediate level zmechanical
zAgNi 10
zchemical
<15V,
z(AgSnO2)
zelectrical
<300mA
z(AgCdO)
power contacts
zAgNi 0.15
z chemical
z electrical
zAgNi 10
10-400V
zAgSnO2
300mA-30A
zAgCdO
Considerations
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Electrical Arc
Contact
current
Load
RArc
U
Supply voltage
Electrical Arc - Effects with Ag Contacts
Switching Voltage [V]
40
30
20
Stable Arc
0.3
0.1
Arc extinguishes
0
10
No ignition of Arc
0
0
0.5 1.0 1.5 2.0
2.5
Contact Distance [mm]
50
Cannot maintain Arc
60
3.0
DC Breaking Capacity
1000
500 W
DC Load Voltage [V]

200 W
100 W
50 W
100
20 W
10 W
10
0,1
DC Load Current [A]
10
Typical Loads for General Purpose Relays
Cooking plates, oven heatings
Heatings, valves and motors in washing machines and dish washers
Compressor motors for refrigerator or air condition
Valves, ignition transformers, pumps in oil or gas heating systems
Building control: several lamp loads, elevators, rolling shutters
Capacitive Load
Capacitive DC-Load
U,I
Capacitive AC-Loads
U
C
Load
Ipeak
U
t
I
I,U
Delay of voltage rise
I=
U
Re -t/T
= RC
rise time in ms
Preferred contact material:

DC-Loads AgSnO, AgNi90/10
AC-Loads AgSnO, AgNi90/10
Inductive Load
$UF
I=
U
R (1-e-t/T)
= RL
rise time in ms
Preferred contact material:

DC-Loads AgNi, (AgSnO)
AC-Loads AgCdO,AgSnO
Load Characteristics
Incandescent
Lamp Load II/IN=10-15
Motor
Load II/IN=5-10
Capacitive
Load II/IN=20-40
(-100)
Solenoid
Load II/IN=(3)-10-20
Relay Switching Behaviour
Contact Lifetime
- Switching current
Parameter:
Op e r a t i o ns
Main influences:
1.0E+ 07
1.0E+ 06
- Load voltage
- Inrush current
1.0E+ 05
- Power factor
- Ambient temperature
- Switching cycle
1.0E+ 04
0
4
S w i tc h in g
5
6
c u r r e n t
[A ]
Reduction of Lifetime at inductive AC-Loads
0,9
Reductionfactor F
0,8
0,7
0,6
0,5
0,4
0,3
1
0,9
0,8
0,7
0,6
0,5
0,4
0,3
0,2
Powerfactor cos
Range of Application for Different ContactMaterials

Application range of different
contact materials overlaps
Contact Material
Au
AgNi 0.15
AgNi90/10
AgCdO
Choice of contact material is optimized

according to relay construction
AgSnO
10
-3
10
-2
10
-1
10
10
Current [A]
Strength of Contact-Materials
Load Character
DC resistiv
DC-inrush
DC-inductiv
DC / AC-low level
AC-medium
AC-heavy
AC-inrush
AC-inductiv
Enviromental aspects
AgNi0,15
++
AgNi 90/10
+
AgCdO
AgSnO2
++
++
++
+
+
+
+
+
++
++
++
+
+
++
+
--
- Suitable for low level loads

- Limited use at main loads according
base contact material
Voltage [V]
Application Range Silver Alloy Gold Plated

10
10
1
Grey range:
No electrical wear
10
White range:
Permanence of gold plating
depends on number of operations
10
-1
-2
10
-3
10
-2
10
-1
10
Insulation Terms and Classification

Insulation characteristic
Basic insulation
Purpose
Insulation for :
Contact-contact in one circuit
Insulation between different contact
circuits
Insulation Class 0 and Class 1 between :
- Control and load circuit
Supplementary insulation together Insulation Class II for :

Protection against electrical shock
with basic insulation
Safe separation of load and control
Double insulation
circuit at safety extra low voltage
Reinforced insulation
Insulation Terms and Classification
Contact behaviour
Purpose
Relays with
Switching of load,
micro contact gap
under insulation aspects the load circuit is to

see like closed
Air-gap relay, cut-off relay
For separation of load
(3mm contact gap)
and voltage supply
Safety relays
Defined behaviour in case of failure
Insulation Requirements
Insulation is determined by appliction standards and depends on
Length of clearence
Length of creepage
Material data (CTI = Comparative Tracking Index)
Environmental influence / polution degree
Control and load voltages
Safety Relays
N.O. and N.C. contacts shall not close at the same time also when a spring breaks
Normal relay
Safety relay
Safety Relays
N.O. and N.C. contacts shall not close at the same time when N.O. is welded
Normal relay
Safety relay
> 0,5mm

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Schematic Application Sketch

- Electrical controlled switch

General Purpose Relays EMEA

The main function...

General Purpose Relays EMEA

General Purpose Relays EMEA

huge range of different loads

able to switch mains voltage

High lights: small

0.1A ... 30A

General Purpose Relays:

Typical Application Area

Switching Current [A]

General Purpose Relays EMEA

Plug in (need a socket) or

Magnetic Systems - Coils

General Purpose Relays EMEA

one or two coils

UA2 (-) / A3 (+)

RESET: UA1(-) / A3 (+)

DC - Bistable Relay Systems

Bistable Remanent Relays

one or two coils

one or two coils

UA2 (-) / A3 (+)

RESET: UA1(-) / A3 (+)

RESET: UA1 / A3 (-+/+-)

low power consumption approx.0.4W

high power consumption 1.2W

General Purpose Relays EMEA

Operating Voltages -Terms

Relay in a not specified state

Relay OFF state

Voltage range depends

Coil Operating Range

Am bien t tem peratu re [ C ]

Electrical Contact, Designation

General Purpose Relays EMEA

Influences on Electrical Contact

General Purpose Relays EMEA

Influences on Switching Contact

General Purpose Relays EMEA

General Purpose Relays EMEA

Electrical Arc - Effects with Ag Contacts

Switching Voltage [V]

General Purpose Relays EMEA

Contact Distance [mm]

Cannot maintain Arc

DC Load Voltage [V]

General Purpose Relays EMEA

DC Load Current [A]

Typical Loads for General Purpose Relays

Cooking plates, oven heatings

Heatings, valves and motors in washing machines and dish washers

Compressor motors for refrigerator or air condition

Valves, ignition transformers, pumps in oil or gas heating systems

Building control: several lamp loads, elevators, rolling shutters

General Purpose Relays EMEA

Delay of voltage rise

General Purpose Relays EMEA

Preferred contact material:

General Purpose Relays EMEA

Preferred contact material: