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Fundamentals of Relay Technology
Fundamentals of Relay Technology
Application Note
105396_en_00 © PHOENIX CONTACT 2012-09-07
Operating voltage range The disturbance level of any interference voltages that are
present can be reduced by connecting an RC element in
The ambient temperature prevailing at the location of use
parallel with the relay coil. This measure also subjects the in-
has a major impact on certain relay operating parameters.
terference voltage to a capacitive load, causing it to col-
As the ambient temperature increases, the coil winding lapse.
heats up, causing the response and release voltages to rise.
At the same time, the maximum permissible coil voltage de-
creases, which means that the usable working range be-
comes restricted as a result.
UINTERF
The diagram below illustrates how the operating voltage be-
haves as a function of the ambient temperature.
Figure 6 Sketch of a relay operating voltage 1.3 Contact side, contact materials
characteristic Given the wide variety of potential applications in the differ-
ent industrial sectors, the relays used must be matched to
I Maximum permissible voltage with 100% operating the various tasks that need to be performed by selecting the
time (OT) and assuming compliance with the coil tem- right kind of contact material.
perature limit
The voltage, current, and power values play an important
II Minimum operate voltage role when determining the suitability of contact materials.
Other criteria include:
1.2 Interference voltages and interference currents
on the coil side – Contact resistance
– Erosion resistance
When inductive or capacitive interference voltages are cou-
– Material migration
pled into the long supply conductors of a relay, this can pre-
vent the relay from operating safely and reliably. – Welding tendency
If the coupled-in voltage exceeds the release voltage de- – Chemical effects
manded by the IEC 61810-1 "relay standard", in extreme In this way, the various contact materials (generally noble
cases the relay may fail to release. In the case of DC relays, metal alloys) can be matched to the relevant areas of appli-
this release voltage is ≥ 0.05 x UN; with AC relays, it is cation.
≥ 0.15 x UN. The adjacent table provides details of some of the key ma-
The same disturbances can occur, when a relay with a low terials.
input power is controlled by an electronics module with an
AC output featuring an RC circuit. The typical leakage cur-
rent from RC elements of this kind (generally in the region of
several mA) provides sufficient control power to prevent the
downstream relay from releasing or even enough power to
excite it.
Switching small loads For the smallest of loads and even greater contact reliability,
double contact relays with gold contacts are used.
Small loads must be processed mainly in applications
where signals must be forwarded to control inputs (e.g., of a The slotted contact spring in this design provides two paral-
PLC). lel contact points with even lower contact resistances and
considerably higher contact reliability.
With these loads, no switching sparks (arcs) occur on the
contacts in the small load range.
1.5 Switching large loads
In addition to the constant cleaning effect due to contact fric-
tion, this switching spark assumes the function of penetrat- A few important points also need to be considered with re-
ing non-conductive contamination layers that are formed on gard to switching processes in the large load range that in-
the contact surfaces of power contacts. volve power contacts made of either silver (Ag) or silver tin
oxide (AgSnO).
A basic distinction must be made between switching DC
and AC loads.
Limit switch
PLC
input card
The 3-wire output is non-isolated and requires both 2.3 Protective circuits
potentials from the power supply source on the output
The moment inductive loads (contactors, solenoid valves,
side to be connected if it is to operate reliably.
motors) are switched off, surge voltages occur and these
When switched off, a permanent reference to the can reach very high amplitudes. Electronic components and
ground (negative potential) is established. In addition, switching elements are particularly susceptible to these. A
this output circuit offers the advantage of an almost protective circuit should therefore always be provided to
constant internal resistance. prevent destruction.
A parallel connection to the load effectively reduces the
switching surge voltage to a harmless level. Depending
upon the solid-state relay output and type of load,
– a free-wheeling diode/suppressor diode (DC only),
– varistor (AC and DC) or
– RC element (AC only)
can provide the necessary protection
Figure 16 3-wire output
Protection
AC output
In order to control the switching and control devices for AC
Load
voltage, a semiconductor for AC voltage (TRIAC or thyristor)
is connected downstream of the solid-state relay element.
As with the DC output, it is particularly important to consider
the maximum operating voltage range and the maximum
continuous load current as a function of the ambient temper-
Figure 18 Protective circuit with DC voltage output
ature.
In addition, the maximum peak reverse voltage of the TRIAC
(e.g., 600 V) is crucial with AC outputs. This must not be ex- Protection
ceeded even in the case of voltage fluctuations or interfer-
ence voltage peaks in order to prevent destruction. That is
why the AC outputs of all solid-state relays from Phoenix
Load
e.g., PLC
IN
e.g., PLC
OUT
e.g., PLC
IN
e.g., PLC
OUT
Remarks
1
e.g., PLC ) Ground (minus) potential from the input and output of the
IN solid-state relay should not be connected.
2
) DC loads must be provided with an effective protective
circuit (e. g., diode).
3)
AC loads must be protected with a varistor or an RC el-
ement.
Figure 22 Example: Position indication with limit stop
contact or initiator