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Small Signal Relay Techincal Info PDF
Small Signal Relay Techincal Info PDF
or + or
+ +
A black coil represents the energized diagrams generally show the coil in its also shown for the reset coil in its reset
state. For latching relays, schematic reset state. Therefore, the coil symbol is state.
PERFORMANCE
Insulation Resistance closure of the normally open contacts. Shock Resistance, Destructive
The resistance value between all mutually (With multiple pole devices the time until The acceleration which can be withstood
isolated conducting sections of the relay, the last contact closes.) This time does by the relay during shipping or installation
i.e. between coil and contacts, across not include any bounce time. without it suffering damage, and without
open contacts and between coil or Release Time (Drop-Out Time) causing a change in its operating charac-
contacts to any core or frame at ground The elapsed time from the initial removal teristics. Usually expressed in Gs.
potential. This value is usually expressed of coil power until the reclosure of the Shock Resistance, Functional
as initial insulation resistance and may normally closed contacts (last contact The acceleration which can be tolerated
decrease with time, due to material with multi-pole) this time does not include by the relay during service without
degradation and the accumulation of bounce. causing the closed contacts to open for
contaminants. Set Time more than the specified time. (usually
Breakdown Voltage (Hi-Pot or Dielectric Term used to describe operate time of a 10s)
Strength) latching relay. Vibration Resistance, Destructive
The maximum voltage which can be Reset Time The vibration which can be withstood by
tolerated by the relay without damage for Term used to describe release time of a the relay during shipping, installation or
a specified period of time, usually latching relay. With a 2-coil magnetic use without it suffering damage, and
measured at the same points as latching relay the time is from the first without causing a change in its operating
insulation resistance. Usually the stated application of power to the reset coil until characteristics. Expressed as an
value is in VAC (RMS) for one minute the reclosure of the reset contacts. With a acceleration in Gs or displacement, and
duration. single coil latching relay, the time is frequency range.
Surge Withstand Voltage measured from the first application of Vibration Resistance, Functional
The ability of the device to withstand an reverse coil voltage until the reclosure of The vibration which can be tolerated by
abnormal externally produced power the reset contact. the relay during service, without causing
surge, as in a lightning strike, or other Contact Bounce (Time) the closed contacts to open for more than
phenomenon. An impulse test waveform Generally expressed in time (ms), this the specified time.
is usually specified, indicating rise time, refers to the intermittent switching Mechanical Life
peak value and fall time. (Fig. 2) phenomenon of the contacts which The minimum number of times the relay
occurs due to the collision between the can be operated under nominal conditions
movable metal parts or contacts, when (coil voltage, temperature, humidity, etc.)
1,500 V the relay is operated or released. with no load on the contacts.
Operate Bounce Time Electrical Life
The time period immediately following The minimum number of times the relay
750 V operate time during which the contacts can be operated under nominal conditions
are still dynamic, and ending once all with a specific load being switched by the
bounce has ceased. contacts.
10 s 160 s Release Bounce Time Maximum Switching Frequency
The time period immediately following This refers to the maximum switching
Fig. 2
release time during which the contacts frequency which satisfies the mechanical
Operate Time (Pull-In or Pick-Up Time) are still dynamic, ending when all bounce life or electrical life under repeated
The elapsed time from the initial has ceased. operations by applying a pulse train at the
application of power to the coil, until the rated voltage to the operating coil.
All Rights Reserved COPYRIGHT Matsushita Electric Works, Ltd.
Definition of Relay Terminology
Life Curve HIGH FREQUENCY CHARACTERISTICS
This is listed in the data column for each
type of relay. The life (number of Isolation V.S.W.R. (Voltage Standing Wave Ratio)
operations) can be estimated from the High frequency signals leak through the High frequency resonance is generated
switching voltage and switching current. stray capacitance across contacts even if from the interference between the input
For example, for a DS relay operating at: the contacts are separated. This leak is signal and reflected (wave) signal.
Switching voltage = 125V AC called isolation. The symbol dB (decibel) V.S.W.R. refers to the ratio of the
Switching current = 0.6A is used to express the magnitude of the maximum value to minimum value of the
The life expectancy is 300,000 leak signal. This is expressed as the waveform. The V.S.W.R. is 1 when there is
operations. However, this value is for a logarithm of the magnitude ratio of the no reflected wave. It usually becomes
resistive load. Be sure to carefully check signal generated by the leak with respect greater than 1.
the actual load before use. to the input signal. The larger the Notes:
Life Curve magnitude, the better the isolation. 1. Except where otherwise specified, the
Insertion Loss tests above are conducted under
1,000 At the high frequency region, signal standard temperature and humidity (15C
disturbance occurs from self-induction, to 35C 59F to 95F, 25 to 75%).
resistance, and dielectric loss as well as 2. The coil impressed voltage in the
30V DC resistance load
from reflection due to impedance switching tests is a rectangular wave at
Life (104)
100
mismatching in circuits. Loss due to any of the rated voltage.
these types of disturbances is called 3. The phase of the AC load operation is
125V AC resistance load insertion loss. Therefore, this refers to the random.
10
magnitude of loss of the input signal. The
smaller the magnitude, the better the
relay.
1 2
Current (A)
PROTECTIVE CONSTRUCTION
Several different degrees of protection are contamination, and also may protect user and chemical stability. This annealing
provided for different relay types, for personnel from a shock hazard. process drives off residual volatiles in the
resistance to dust, flux, contaminating Flux-Resistant Type plastics, insuring a contaminant free
environments, automatic cleaning, etc. In this type of construction, solder flux environment inside the sealed relay,
Open Type penetration is curtailed by either insert resulting in more stable contact
For reasons of cost, some devices are not molding the terminals with the header, or resistance over life.
provided with any enclosure. It is usually by a simple sealing operation during Hermetic Seal
assumed that the end application will be manufacturing. The plastic sealed type is not a true
in an overall enclosure or protective Sealed Type hermetic seal, there is an exchange of
environment. This type of sealed relay totally excludes gas molecules through the plastic cover
Dust Cover Type the ingress of contaminants by way of a over time. The only true hermetic seals
Most standard relays are provided with a sealing compound being applied to the are metal to metal and glass to metal. The
dust cover of some type. This protects the header/cover interface. The constituent entire device is purged with dry nitrogen
relay from large particulate components are annealed for physical gas prior to sealing, improving reliability.
Base
Metal case
1 3 4 5 6
12 10 9 8 +
Direction indication*
TX relay
+
Fig. 3 12 10 9 8 7
Direction indication*
1 Coil Latching Type TX relay
LED wired
Fig. 5 HC relay
Relay with a latching construction that can
maintain the on or off state with a pulse Fig. 6
input. With one coil, the relay is set or
reset by applying signals of opposite
polarities. (Fig. 4)
1 3 4 5
+
12 10 9 8
Direction indication*
TX relay
Fig. 4
TERMINAL CONFIGURATION
PC board PC board
PC board through hole Quick connect
Type self-clinching surface-mount Plug-in terminal Screw terminal
terminal terminal
terminal terminal
Typical relay
type
Terminal
configuration
MOUNTING METHOD
Terminal socket
Type Insertion mount Surface mount Socket mount TM relay TMP type
mount
;
;; ;
;
Mounting
configuration Terminal
Socket
RELAY COIL
AC operation type resistance due to temperature rise, must humming is stopped, but with a distorted
For the operation of AC relays, the power be given consideration for the worst waveform, that function is not displayed.
source is almost always a commercial possible condition of relay operation, Fig. 1 below shows an example of
frequency (50 or 60Hz) with standard making it necessary to consider the waveform distortion.
voltages of 6, 12, 24, 48, 115, and 240V current value as 1.5 to 2 times the pick-up If the power source for the relay operating
AC. Because of this, when the voltage is current. Also, because of the extensive circuit is connected to the same line as
other than the standard voltage, the use of relays as limit devices in place of motors, solenoids, transformers, and
product is a special order item, and the meters for both voltage and current, and other loads, when these loads operate,
factors of price, delivery, and stability of because of the gradual increase or the line voltage drops, and because of this
characteristics may create decrease of current impressed on the coil the relay contacts suffer the effect of
inconveniences. To the extent that it is causing possible delay in movement of vibration and subsequent burn damage.
possible, the standard voltages should be the contacts, there is the possibility that In particular, if a small type transformer is
selected. the designated control capacity may not used and its capacity has no margin of
Also, in the AC type, shading coil be satisfied. Thus it is necessary to safety, when there is long wiring, or in the
resistance loss, magnetic circuit eddy exercise care. The DC type relay coil case of household used or small sales
current loss, and hysteresis loss exit, and resistance varies due to ambient shop use where the wiring is slender, it is
because of lower coil efficiency, it is temperature as well as to its own heat necessary to take precautions because of
normal for the temperature rise to be generation to the extent of about 0.4%/C, the normal voltage fluctuations combined
greater than that for the DC type. and accordingly, if the temperature with these other factors. When trouble
Furthermore, because humming occurs increases, because of the increase in pic develops, a survey of the voltage situation
when below the pick-up voltage and when k-up and drop-out voltages, care is should be made using a synchroscope or
above the rated voltage, care is required required. similar means, and the necessary
with regard to power source voltage Energizing voltage of AC coil counter-measures should be taken, and
fluctuations. In order to have stable operation of the together with this determine whether a
For example, in the case of motor starting, relay, the energizing voltage should be special relay with suitable excitation
if the power source voltage drops, and basically within the range of +10%/-15% characteristics should be used, or make a
during the humming of the relay, if it of the rated voltage. However, it is change in the DC circuit as shown in Fig.
reverts to the restored condition, the necessary that the waveform of the 2 in which a capacitor is inserted to
contacts suffer a burn damage and voltage impressed on the coil be a sine absorb the voltage fluctuations.
welding, with the occurrence of a false wave. There is no problem if the power In particular, when a magnetic switch is
operation self-maintaining condition. source is commercially provided power, being used, because the load becomes
For the AC type, there is an inrush current but when a stabilized AC power source is like that of a motor, depending upon the
during the operation time (for the used, there is a waveform distortion due application, separation of the operating
separated condition of the armature, the to that equipment, and there is the circuit and power circuit should be tried
impedance is low and a current greater possibility of abnormal overheating. By and investigated.
than rated current flows; for the adhered means of a shading coil for the AC coil,
condition of the armature, the impedance
is high and the rated value of current
flows), and because of this, for the case of
several relays being used in parallel
connection, it is necessary to give
consideration to power consumption.
DC operation type Sine wave Approximate keystone wave Waveform with a
this harmonic included
For the operation of DC relays, standards
exist for power source voltage and Fig. 1 Distortion in an AC stabilized power source
current, with DC voltage standards set at
5, 6, 12, 24, 48, and 100V, but with regard
to current, the values as expressed in T
catalogs in milliamperes of pick-up Switch
current. 100V AC
However, because this value of pick-up
24V DC C R Relay coil
current is nothing more than a guarantee
of just barely moving the armature, the
variation in energizing voltage and
Fig. 2 Voltage fluctuation absorbing circuit using a condenser
resistance values, and the increase in coil
Load
somewhat weakened, and it is necessary original manufacture.
to take care since the resistance to Shown on the right, is a circuit driven by
vibration and shock is reduced. Also the same power supply (battery, etc.) for
ordinarily the following must be given both the coil and contact.
thought.
Coil temperature rise deformity of the insulation material, or the resistance method. However, when
In addition to being a requirement for relay occurrence of fire hazards. complying with the Electrical Appliance
operation stability, the maximum In actual use with E-type insulation, when and Material Safety Law, this becomes
continuous impressed coil voltage is an the ambient temperature is 40C 104F, a 75C 167F.
important constraint for the prevention of temperature rise limit of 80C 176F is
such problems as thermal deterioration or thought to be reasonable according to the
Temperature rise due to pulse voltage Pick-up voltage change due to coil range, but for miniature types it is for the
When a pulse voltage with ON time of less temperature rise (hot start) most part 1/2 cycle (about 10ms).
than 2 minutes is used, the coil In DC relays, after continuous passage of However, for the somewhat large type
temperature rise bares no relationship to current in the coil, if the current is turned relay where bounce is large, the operate
the ON time. This varies with the ratio of OFF, then immediately turned ON again, time is 7 to 16ms, with release time in the
ON time to OFF time, and compared with due to the temperature rise in the coil, the order of 9 to 18ms Also, in the case of DC
continuous current passage, it is rather pick-up voltage will become somewhat operation, to the extent of large coil input,
small. The various relays are essentially higher. Also, it will be the same as using it the operating time is rapid, but if it is too
the same in this respect. (Fig. 4) in a higher temperature atmosphere. The rapid, the A contact bounce time is
Current passage time % resistance/temperature relationship for extended.
Temperature rise copper wire is about 0.4% for 1C, and Stray circuits (bypass circuits)
For continuous passage with this ratio the coil resistance In the case of sequence circuit
value is 100%
ON : OFF = 3 : 1 About 80% increases. That is, in order to operate of construction, because of bypass flow or
ON : OFF = 1 : 1 About 50% the relay, it is necessary that the voltage alternate routing, it is necessary to take
be higher than the pick-up voltage and the care not to have erroneous operation or
ON : OFF = 1 : 3 About 35%
pick-up voltage rises in accordance with abnormal operation. To understand this
the increase in the resistance value. condition while preparing sequence
However, for some polarized relays, this circuits, as shown in Fig. 5, with 2 lines
Voltage
1:1
rate of change is considerably smaller. written as the power source lines, the
Operate time upper line is always B and the lower line
In the case of AC operation, there is v (when the circuit is AC, the same
extensive variation in operate time thinking applies). Accordingly the B side
Time depending upon the point in the phase at is necessarily the side for making contact
which the switch is turned ON for coil connections (contacts for relays, timers,
Fig. 4
excitation, and it is expressed as a certain limit switches, etc.), and the v side is the
Gradual increase of coil impressed with mixture of gradual increase of initial test (trial production), it shows
voltage and suicide circuit impressed voltage for the coil and a favorable operation, but as the number of
When the voltage impressed on the coil is sucide circuit. In the timing portion for operations increases, contact blackening
increased slowly, the relay transferring relay R1, when the timing times out, (carbonization) plus the chattering of the
operation is unstable, the contact chattering occurs causing trouble. In the relay creates instability in performance.
pressure drops, contact bounce
increases, and an unstable condition of
Instability point
contact occurs. This method of applying R1 a R2a
Switch
voltage to the coil should not be used, and
R1 b R2b
consideration should be given to the
X X
method of impressing voltage on the coil SW
ON
(use of switching circuit). Also, in the case E
;;;
End of coil winding
+ +
of current, the corrosion can be said to be
;;;;
+
Relay coil Iron core Relay coil Iron core
the result of the occurrence of electrolytic +
;
R (Insulation Start of coil winding R (Insulation
corrosion. Because of the possibility of resistance) resistance)
Switch
open circuits occurring, attention should
be given to the following points.
[1] The B side of the power source should
be connected to the chassis. (Refer to Fig. Judgement: Good (Fig. 11) Judgement: No good (Fig. 12)
9) (Common to all relays)
[2] In the case where unavoidably the v Switch
Bobbin
side is grounded, or in the case where
;;;
+ + +
;;;;
grounding is not possible. + Iron core
+
Relay coil Relay coil Iron core
(1) Insert the contacts (or switch) in the B
;
Bobbin R (Insulation
side of the power source, and connect the Switch
resistance)
CONTACT
The contacts are the most important exercise care with regard to control ambient conditions, change in the desired
elements of relay construction. Contact capacity. In the case of DC, there is no contact resistance, and the absolute
performance conspicuously influenced by zero current point such as there is with value. Please use relays with AgPd
contact material, and voltage and current AC, and accordingly, once a cathode arc contacts when minute analog load control
values applied to the contacts (in has been generated, because it is difficult or contact resistance no higher than 100
particular, the voltage and current to quench that arc, the extended time of m is desired (for measurement and
waveforms at the time of application and the arc is a major cause. In addition, due wireless applications, etc.).
release), the type of load, frequency of to the direction of the current being fixed, [Current]
switching, ambient atmosphere, form of the phenomenon of contact shift, as noted The current at both the closing and
contact, contact switching speed, and of separately below, occurs in relation to the opening time of the contact circuit exerts
bounce. contact wear. Ordinarily, the approximate important influence. For example, when
Because of contact transfer, welding, control capacity is mentioned in catalogs the load is either a motor or a lamp, to the
abnormal wear, increase in contact or similar data sheets, but this alone is not extent of the inrush current at the time of
resistance, and the various other sufficient. With special contact circuits, for closing the circuit, wear of the contacts,
damages which bring about unsuitable the individual case, the maker either and the amount of contact transfer
operation, the following items require full estimates from the past experience or increase, and contact welding and contact
investigation. makes test on each occasion. Also, in transfer make contact separation
*We recommend that you verify with one catalogs and similar data sheets, the impossible.
of our sales offices. control capacity that is mentioned is
1. Contact circuit voltage, current, and limited to resistive load, but there is a
load broad meaning indicated for that class of
[Voltage, AC and DC] relay, and ordinarily it is proper to think of
When there is inductance included in the current capacity as that for 125V AC
circuit, a rather high counter emf is circuits.
generated as a contact circuit voltage, Minimum applicable loads are given in the
and since, to the extent of the value of that catalog; however, these are only provided
voltage, the energy applied to the as a guide to the lower limit that the relay
contacts causes damage with is able to switch and are not guaranteed
consequent wear of the contacts, and values. The level of reliability of these
transfer of the contacts, it is necessary to values depends on switching frequency,
AgCd Exhibits the conductivity and low contact resistance of silver as well as excellent resistance to welding. Like silver,
(silver-cadmium) it easily develops a sulfide film in a sulfide atmosphere.
Hardness and melting point are high, arc resistance is excellent, and it is highly resistant to material transfer.
Contact AgW
However, high contact pressure is required. Furthermore, contact resistance is relatively high and resistance to
Material (silver-tungsten)
corrosion is poor. Also, there are constraints on processing and mounting to contact springs.
AgNi
Equals the electrical conductivity of silver. Excellent arc resistance.
(silver-nickel)
AgPd At standard temperature, good corrosion resistance and good sulfidation resistance. However, in dry circuits,
(silver-palladium) organic gases adhere and it easily develops a polymer. Gold clad is used to prevent polymer buildup. Expensive.
Combines perfect corrosion resistance and hardness. As plated contacts, used for relatively light loads. In an
Rh plating
organic gas atmosphere, care is required as polymers may develop. Therefore, it is used in hermetic seal relays
(rhodium)
(reed relays, etc.) . Expensive.
Au with its excellent corrosion resistance is pressure welded onto a base metal. Special characteristics are
Au clad
uniform thickness and the nonexistence of pinholes. Greatly effective especially for low level loads under relatively
(gold clad)
Surface adverse atmospheres. Often difficult to implement clad contacts in existing relays due to design and installation.
Finish
Au plating Similar effect to Au cladding. Depending on the plating process used, supervision is important as there is the
(gold plating) possibility of pinholes and cracks. Relatively easy to implement gold plating in existing relays.
Au flash plating Purpose is to protect the contact base metal during storage of the switch or device with built-in switch. However, a
(gold thin-film plating) certain degree of contact stability can be obtained even when switching loads.
lengthens. Effective when connected to both the next time. Test to confirm. Use a capacitor
r
G G contacts if the power supply voltage is 24 or 48V with a breakdown voltage of 200 to 300V. Use
c and the voltage across the load is 100 to 200V. AC type capacitors (non-polarized) for AC
circuits.
The diode connected in parallel causes the Use a diode with a reverse breakdown voltage
Contact energy stored in the coil to flow to the coil in the at least 10 times the circuit voltage and a
Inductive load
form of current and dissipates it as joule heat at forward current at least as large as the load
Diode
Diode NG G the resistance component of the inductive load. current. In electronic circuits where the circuit
circuit
This circuit further delays the release time voltages are not so high, a diode can be used
compared to the CR circuit. (2 to 5 times the with a reverse breakdown voltage of about 2 to
release time listed in the catalog) 3 times the power supply voltage.
Diode Contact
Inductive load
and
Effective when the release time in the diode Use a zener diode with a zener voltage about
zener NG G
circuit is too long. the same as the power supply voltage.
diode
circuit
Load
Power C
Load
Mounting the Protective Device Type of Load and Inrush Current Type of load Inrush current
In the actual circuit, it is necessary to The type of load and its inrush current Resistive load Steady state current
locate the protective device (diode, characteristics, together with the
10 to 20 times the
resistor, capacitor, varistor, etc.) in the switching frequency, are important factors Solenoid load
steady state current
immediate vicinity of the load or contact. If which cause contact welding. Particularly 5 to 10 times the
located too far away, the effectiveness of for loads with inrush currents, measure Motor load
steady state current
the protective device may diminish. As a the steady state and inrush current. Incandescent lamp 10 to 15 times the
guide, the distance should be within Then select a relay which provides an load steady state current
50cm. ample margin of safety. The table on the Approx. 3 times the
Mercury lamp load
Abnormal Corrosion during High right shows the relationship between steady state current
Frequency Switching of DC Loads typical loads and their inrush currents. Sodium vapor lamp 1 to 3 times the
(spark generation) Also, verify the actual polarity used since, load steady state current
If, for example, a DC valve or clutch is depending on the relay, electrical life is Capacitive load
20 to 40 times the
switched at a high frequency, blue-green affected by the polarity of COM and NO. steady state current
rust may develop. This occurs from the 5 to 15 times the
Transformer load
reaction of nitrogen and oxygen in the air steady state current
when sparks (arc discharge) are
generated during switching.
Contacts L
i io C i io
i io
(4) Motor Load i/io ] 5 to 10 times (5) Solenoid Load (6) Electromagnetic Contact Load (7) Capacitive Load
i/io ] 10 to 20 times i/io ] 3 to 10 times i/io ] 20 to 40 times
i io
i io i io
i io
Equivalent circuit
+
Contacts
Stray capacitance
Added resistor Wire
10 to 50 of wire
(100 to 300m)
Fig. 16
Fig. 18
Dummy Resistor
Since voltage levels at the contacts used
in low current circuits (dry circuits) are R1
Commercial AC power
Home AC generator
low, poor conduction is often the result. R1
N.C. N.O. Push-botton
One method to increase reliability is to COM
switch
Load
add a dummy resistor in parallel with the M
Load
load to intentionally raise the load current R R Relay coil
reaching the contacts. R2
Avoid Circuits Where Shorts Occur R2
Between Form A and B Contacts 1) R1, R2 : Contacts for R 2) 3) R1, R2 : Contacts for R
R : Double pole relay R : Double pole relay
(Fig. 19)
1) The clearance between form A and B
contacts in compact control components
Fig. 19
is small. The occurrence of shorts due to
arcing must be assumed. Shorts Between Different Electrodes circuits. This is not a problem that can be
2) Even if the three N.C., and COM Although there is a tendency to select determined from sequence circuit
contacts are connected so that they short, miniature control components because of diagrams. The construction of the control
a circuit must never be designed to allow the trend toward miniaturizing electrical component itself must be examined and
the possibility of burning or generating an control units, care must be taken when sufficient margin of safety must be
overcurrent. selecting the type of relay in circuits where provided especially in creepage between
3) A forward and reverse motor rotation different voltages are applied between electrodes, space distance, presence of
circuit using switching of form A and B electrodes in a multi-pole relay, especially barrier, etc.
contacts must never be designed. when switching two different power supply
LATCHING RELAYS
Latching relays are shipped from the
factory in the reset state. A shock to the (a) Parallel connection of set coils (b) Parallel connection of set coils
relay during shipping or installation may (+) (+)
Bad example
Fig. 21 Fig. 22
Two Coil Latch Induction Voltage is generated on the reverse side coil when voltage, you must be careful of the
Each coil in a 2-coil latch relay is wound voltage is applied and shut off to each coil. reverse bias voltage when driving
with a set coil and a reset coil on the same Although the amount of induction voltage transistors.
iron cores. Accordingly, induction voltage is about the same as the rated relay
AMBIENT ENVIRONMENT
1. Ambient Temperature and 3. NOx Generation on separate plates, using a rubber sheet
Atmosphere When a plastic sealed type relay is used to absorb the shock, and changing the
Be sure the ambient temperature at the in an atmosphere high in humidity to direction of the shock to a perpendicular
installation does not exceed the value switch a load which easily produces an angle.
listed in the catalog. Furthermore, arc, the NOx created by the arc and the 5. Influence of External Magnetic
environmentally sealed types (plastic water absorbed from outside the relay Fields
sealed type, metallic hermetic seal type) combine to produce nitric acid. This Permanent magnets are used in reed
should be considered for applications in corrodes the internal metal parts and relays and polarized relays (including NR
an atmosphere with dust, sulfur gases adversely affects operation. relays), and their movable parts are
(SO2, H2 S), or organic gases. Avoid use at an ambient humidity of constructed of ferrous materials. For this
2. Silicon Atmosphere 85%RH or higher (at 20C 68F). If use at reason, when a magnet or permanent
Please use something other than silicon high humidity is unavoidable, consult us. magnet in any other large relay,
based materials (silicon rubber, silicon oil, 4. Vibration and Shock transformer, or speaker is located nearby,
silicon-based coatings, and silicon bulking If a relay and magnetic switch are the relay characteristics may change and
agents, etc.) in the vicinity of the relay mounted next to each other on a single faulty operations may result. The
since their use will generate volatile gas. plate, the relay contacts may separate influence depends on the strength of the
When contacts are switched in such an momentarily from the shock produced magnetic field and it should be checked at
environment, silicon may adhere to the when the magnetic switch is operated and the installation.
contacts and lead to contact failure (in result in faulty operation.
plastic seal types, too). Countermeasures include mounting them
PROCESSING CONSIDERATIONS
1. Handling supplied in prime condition. Some key researched carefully. An unsealed relay is
State of the art relays are precision areas of concern: prone to internal flux contamination which
mechanical devices and as such are (1) Terminals should not be handled in can compromise contact performance,
sensitive to abusive handling practices. order to prevent contamination of the and ideally should be hand soldered.
Every attempt is made during their surface finish. This could lead to Flux-resistant relays are available which
manufacture to preclude any anomalies. solderability problems. will prevent flux migration through the
Relays are packed in a variety of ways to (2) Terminal layout and P.C. board hole terminal-header interface. These and
best protect them during shipment and pattern should match. Any misalignment sealed relays are compatible with mist
subsequent handling. These include the caused by mis-registered P.C. board foam or spray fluxing operations, however
use of Egg Crate type inserts which holes can lead to severe stress on the Flux-resistant types are not totally
support the relay and prevent damage to relay, compromising performance and sealed which precludes washing
the terminals, foam trays which prevent reliability (seal integrity). operations, and makes a non-active flux
shock damage, and tubes similar to those (3) The storage temperature specification almost a necessity.
used by semiconductor manufacturers for should be observed. Pre-heating the board assembly prior to
machine dispensing and assembly. (4) Relays should be stored and handled soldering Flux-resistant types will dry
During incoming inspection and in a suitably clean area. the flux and further help to prevent flux
subsequent customer handling 2. Fluxing being driven into the relay during the
operations, care should be taken so as Depending upon the type of relay soldering operation.
not to degrade the device which has been involved, fluxing procedures should be
MOUNTING CONSIDERATIONS
Top View and Bottom View the vibration and shock resistance of buildup.
Relays used for PC boards, especially the Form B contacts while the coil is not This also applies when a large number of
flat type relays, have their top or bottom excited is greatly affected by the mounting boards mounted with relays are installed
surface indicated in the terminal wiring direction of the relay. as in a card rack. Be sure the ambient
diagrams. Contact Reliability temperature of the relay does not exceed
Relay with Mounting the relay so the surfaces of its the value listed in the catalog.
terminals viewed contacts (fixed contacts or movable Influence of Adjacent Mounting of
from the bottom contacts) are vertical prevents dirt and Polarized Relays
(terminals cannot dust as well as scattered contact material When polarized relays are mounted close
be seen from the (produced due to large loads from which together, their characteristics change.
top) arcs are generated) and powdered metal Since the affect of adjacent mounting
Relay with from adhering to them. differs according to the type of relay, refer
terminals viewed Furthermore, it is not desirable to switch to the data for the particular type.
from the top (all both a large load and a low level load with Panel Mounting
terminals can be a single relay. The scattered contact -Do not remove the panel. It has a special
seen from the top) material produced when switching the function. (It will not come off under normal
Note during PC large load adheres to the contacts when handling.)
board pattern switching the low level load and may -When installing please use washers to
design (NL, NC) cause contact failure. Therefore, avoid prevent damage and deformation. Please
mounting the relay with its low level load keep the tightening torque to within 0.49
Mounting Direction contacts located below the large load to 68.6 N (5 to 7 kgf). Also, please use a
Mounting direction is important for contacts. spring washer to prevent it from coming
optimum relay characteristics. Adjacent Mounting loose.
Shock Resistance When many relays are mounted close Tab Terminals
It is ideal to mount the relay so that the together, abnormally high temperatures As a guide, use a quick connect mounting
movement of the contacts and movable may result from the combined heat pressure of 40 to 70N {4 to 7 kgf} for
parts is perpendicular to the direction of generated. Mount relays with sufficient relays with tab terminals.
vibration or shock. Especially note that spacing between them to prevent heat
METHOD OF MOUNTING
The direction of mounting is not
specifically designated, but to the extent
possible, the direction of contact
movement should be such that vibration
and shock will not be applied.
When a terminal socket is used
After drilling the mounting holes, the
terminal socket should be mounted Fig. 24
making certain the mounting screws are When all four of the projections are
not loose. DIN standard sockets are visible from the back side of the mounting
available for one-touch mounting on DIN Fig. 23 panel, the mounting is completed and the
rail of 35mm 1.378 inch width. The socket should be pushed through socket is fastened.
When reversible terminal sockets are the opening in the mounting panel until To remove the socket, the projections on
used the projections on the side of the the side of the mounting bracket should
The reversible terminal sockets (HC, HL mounting bracket extend out over the be pushed inward and at the same time
socket) are for one-touch mounting. (A back surface. (Fig. 24) the body of the socket should be pushed
panel thickness of 1 to 2mm .039 to .079 lightly from the back side. The socket can
inch should be used.) (Fig. 23) then be removed from the panel.
1. Does circuit design take into account electrolytic corrosion of the coil?
2. Are transistors and other circuit components protected rom counter electromotive force that develops across the
relay coil?
3. Is the circuit designed so the relay coil is left deenergized while the relay is inactive for long period of time?
4. Is the relay operated within the ratings approved by the relevant international standard (if compliance is required)?
5. Is the circuit protected from malfunction when the relays activation and/or deactivation time varies considerably?
6. Is the circuit protected from malfunctions that might result from relay contact bounce?
7. Is the circuit protected from malfunction when a high-sensitivity self-holding relay, such as NR type, is to be used?
8. When there are two or more sets of contacts (2T) in a relay, arc discharges from load switching may cause short
Circuit Design circuits across the two or more sets of contacts. Is the circuit designed to suppress such arc discharges?
9. Item 8 above also requires special attention when loads are supplied from separate power sources.
10. Does the post-installation insulation distance comply with the requirement of the relevant international standard or
the Electrical Appliance and Material Control Law?
11. Is the circuit protected from malfunction when the relay is to be driven by transistors?
12. When the SCR is used for on/off control, the relay activation tends to synchronize with the line frequency, resulting
in an extremely shortened life. Was the relay tested in a real circuit or with a real load?
13. Does the PC board design take into account use of on-board relay?
14. RF signals may leak across relays open contacts. Check for adequate contact isolation and use RF relays as
needed.
1. Is the relay protected from solder chips and flux when it is manually soldered?
2. Are preparations for flux application and automatic soldering complete?
3. Is the PC board cleaning process designed to minimize adverse affects to the relays?
4. Are adequate separations provided between polarized or reed relays to prevent magnetic coupling?
5. Are the relay terminals free from stress in the socket?
6. Polarized relays characteristics may be affected by strong external magnetic field. Are the relays installed away
from such fields?
Installation and 7. If very long leads (100 to 300 meters) are used to connect the load, the stray capacity existing across the leads
Connection may cause a surge current. Was the relay tested with a real load?
8. Unless otherwise specified, all relay terminals should be soldered at 250C 482F within 5 sec. or at 350C 662F
within 3 sec.
9. A badly warped PC board can cause stress to the relay terminals which may lead to degraded relay
characteristics.
10. Glass shot should not be used to clean the PC board of solder flux. This may cause relay malfunction due to glass
powder becoming lodged in the relays internal structure.
11. Relays should always be used with their plastic shields installed, or degraded relay performance may result.
12. Do not cut away any relay terminal as the stress may cause degraded relay performance.
Reliability Measures
The following list contains some of the 1. Degree of Reliability 4. Failure Rate
most popular reliability measures: Degree of reliability represents Failure rate includes mean failure rate and
Sample percentage ratio of reliability. For momentary failure rate.
Reliability measure example, if none of 10 light bulbs has Mean failure rate is defined as follows:
representation
Degree of reliability R(T) 99.9% failed for 100 hours, the degree of
MTBF 100 hours reliability defined in, 100 hours of time is Mean failure rate = Total failure count/total
MTTF 100 hours 10/10 = 100%. If only three bulbs operating hours
remained alive, the degree of reliability is
Failure rate 20 fit, 1%/hour
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B10
(c) Safe life
;;;;
[2] Bathtub Curve to wear of fatigue. Preventive
Failure rate
Products failure rate throughout its maintenance is effective for this type of
;;;
lifetime is depicted as a bathtub curve, as failure. The timing of a relays wear-out m
shown below. Failure rate is high at the failure can be predicted with a certain
beginning and end of its service lifetime. accuracy from the past record of uses. 63%
(I) Initial failure period The use of a relay is intended only in the
The high failure rate in the initial failure accidental failure period, and this period
Time
period is derived from latent design virtually represents the service lifetime of
errors, process errors, and many other the relay.
this period, called accidental failure () e (2) The Weibull probability chart is easy to
period, failures occurs at random along use.
the time axis. While zero accidental failure where (3) Different types of failures can be
rate is desirable, this is actually not m : Figure parameter identified on the chart.
practical in the real world. : Measurement parameter
: Position prameter The following describes the correlation
with the bathtub curve. The value of the
parameter m represents the type of the
failure.
(1) When m < 1: Initial failures
Failure rate
m>1
m<1
m=1
Time
Ry
R2
Ry
Snap action
Non-pulse signal Pulse signal (square wave)
(Characteristic of relay with voltage rise
and fall of voltage)
Unlike the characteristic when voltage is IB
impressed slowly on the relay coil, this is Ry
are 1 ms or less.
ON
Ry
OFF
(No Good) Without snap action (Good) Snap action
Fig. 3
GND
retained at the relay coil which may cause When the signal from the transistors
incomplete restoration and faulty collector is taken and used to drive T1 T2
operation. By using DC coils, there may another circuit as shown in the figure on
be a reduction in; the danger of the right, a minute dark current flows to
incomplete restoration, the contact the relay even if the transistor is off. This
pressure, and the vibration resistance. may cause the problems described IO: dark current (No good)
This is because the drop-out voltage is above. (Fig. 6) Fig. 6 Connection to the next stage through
10% or more of the rated voltage, a low collector
Fig. 9
R2
Ry Ry
Ry
LED R1
Fig. 10
Triac drive
When an electronic circuit using a direct
drive from a triac, the electronic circuit will L
Regular circuit
relay, but from a practical viewpoint, the Regulated power supply or voltage stabilizer.
relay should be operated within the C Electronic circuit
Ry
Ry
Battery
(C)
M Motor
C
Fig. 13
Diode bridge
0.3 to 0.5mm
.012 to .020 inch Bevel of radius
(Care) (Good) (Good) Contact on both surfaces
Fig. 15 Fig. 16
10 10 14
Copper foil Copper foil Copper foil
9 0.0018mm 9 .035mm 60C 140F 13 .070mm 60C 140F
.0007 inch .001 inch 12 .003 inch
8 8 11
40C 104F 40C 104F
7 7 10
60C 140F 9
Current, A
Current, A
Current, A
6 6
8
40C 104F 5 20C 68F 20C 68F
5 7
4 4 6
20C 68F 10C 50F 5 10C 50F
3 3 4
10C 50F
2 2 3
2
1 1
1
0 0 0
0 0.2 0.5 1.0 1.5 2.0 2.5 3.0 0 0.2 0.5 1.0 1.5 2.0 2.5 3.0 0 0.5 1.0 1.5 2.0 2.5 3.0
0 .008 .020 .039 .059 .079 .098 .118 0 .008 .020 .039 .059 .079 .098 .118 0 .020 .039 .059 .079 .098 .118
Conductor width, mm inch Conductor width, mm inch Conductor width, mm inch
30
.035 50 2.0 .079
Resistance, m
25 .001 30
3.0 .118
20
20
.018 10
.0007
15 5
3
10
2
5
1
0
0 0.5 1.0 1.5 2.0 2.5 3.0 0.5 1 2 3 5 10 20 30 50 100 200
0 .020 .039 .059 .079 .098 .118 .197 .394 .7871.1811.969 3.937 7.874 11.811 19.685 39.37 78.74
Conductor width, mm inch Conductor lenth (cm inch)
Fig. 20 Fig. 21
Do not clean dust-cover type relays and use materials which are chemical
6. Cleaning flux-resistant type relays by immersion. resistant. Select the suitable relay or
Even if only the bottom surface of the PC solvent by referring to the cleaning solvent
board is cleaned (e.g. with a brush), compatibility chart below.
careless cleaning may cause cleaning Cleaning with the boiling method is
solvent to penetrate the relay. recommended. Avoid ultrasonic cleaning
Plastic sealed type relays can be on relays. Use of ultrasonic cleaning may
cleaned by immersion. Use a Freon- or cause breaks in the coil or slight sticking
alcohol-based cleaning solvent. Use of of the contacts due to the ultrasonic
other cleaning solvents (e.g. Trichlene, energy.
chloroethene, thinner) may damage the
relay case. However, some types of relays
What is a Surface Mount Relay? We applied the experience gained from electromagnetic relays compatible with
1. From IMT to SMT our advanced relay technologies to surface mount technologies such as IRS
Conventional insertion mount technology produce high-performance and VPS.
(IMT) with some 30 years of history is now
;;
Insertion Mount Technology vs. Surface Mount Technology
being replaced with surface mount
technology (SMT). Components leads are inserted into lead Resistor
Relay
Solid-state components such as resistors, Insertion Mounting holes of PC board and are soldered to
ICs, and diodes can withstand high heat Technology: IMT copper pads on the other side of the board
using flow-soldering techniques. PC board
;
stresses from reflow soldering because
they use no mechanical parts. In contrast, Components are placed on copper pads
the conventional electro-mechanical precoated with paste solder and the board Relay Chip resistance
Surface Mount
relays consisting of solenoid coils, assembly is heated to solder the
Technology (SMT)
springs, and armatures are very sensitive components on the pads (reflow PC board IC
;
;
soldering).
to thermal stress from reflow soldering.
For small, lightweight components Our SMT relays are supplied in stick
2. Relay Installation
Such as chip components, a self- packaging compatible with automatic
alignment effect can be expected if small placement processes. We also offer tape
placement errors exist. However, this packaging at customer request.
effect is not as expected for electro- Holding Pressure
mechanical components such as relays, Direction A: Less than 9.807 N (less than 1,000 gf)
and they require precise positioning on Direction B: Less than 9.807 N (less than 1,000 gf)
Direction C: Less than 9.807 N (less than 1,000 gf)
their soldering pads. A C B
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If SMT relays sustain excessive
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mechanical stress from the placement
machines pickup head, their performance
cannot be guaranteed. (ex. TQ-SMD type)