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Using Flyback Diodes in Relays

Prevents Electrical Noise in Your
Circuits
What is a Flyback Diode and How Does it Work?

A flyback diode, also known as a snubber diode or freewheeling diode, is an

important electrical component used to prevent voltage and current spikes
when controlling inductive loads in circuits.

The key property of inductors and relays is that they resist changes in current
flowing through them. When the power applied to an inductor or relay coil is
suddenly reduced or interrupted, the magnetic field collapses very quickly,
causing a large voltage spike as energy is released. This can damage switching
transistors and integrated circuits.

A flyback diode provides a path for current to continue flowing when power to
the load is removed. This gradually dissipates the energy stored in inductive
components without allowing dangerous voltage spikes.

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A flyback diode conducts backward current when power to inductive load is

disrupted

. are almost always placed across the terminals of inductive loads such as relays,
solenoids, motors, or transformers. They can be individual diodes wired in
parallel or included within the component itself.

Now let’s take a deeper look at the importance of controlling relay switching
noise.

Why Electrical Noise Prevention is Important with Relays

Relays are a vital category of electromechanical component used to control

power delivery and signals in countless industrial, commercial and consumer
electronic systems. From automotive computers to HVAC equipment to
vending machines, relays enable automated switching of higher
voltages/currents than could be handled by low power circuitry alone.

However, relays do present challenges due to the inductance inherent in their

solenoid coils used for actuation along with connections to motors or heaters.
Rapid interruption of current through inductors creates reverse EMF spikes
and electrical noise which can interfere with microcontrollers and other
sensitive digital logic, even causing damage.

Some key negative impacts associated with relay switching noise include:

Reset or spontaneous triggering — Noise glitches may inadvertently

trigger logic level changes that reset processors, activate components
incorrectly or cause erractic opereration.

False signals — Transients can resemble legitimate data signals, confusing

digital systems by simulating buttons being pushed or sensor readings that
didn’t actually occur.

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Component failures — Excessive flyback voltages beyond transistor or IC

voltage tolerances leads to breakdown and permanent damage over time.

Electromagnetic interference (EMI) — High frequency noise may disrupt

performance of wireless communication equipment or leak to cause FCC
violations.

So suppressing electrical noise generated by relay switching is critical for

preventing system malfunctions, instability, premature breakdowns and
interference issues across countless applications.

Proper application of flyback diodes helps mitigate such problems by diverting

and dissipating inductive kickback safely when interrupting current to relay
coils.

Key Factors When Selecting Flyback Diodes

In choosing an appropriate flyback diode for protecting relay or solenoid

switching circuits, some key parameters need to be considered:

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1. Reverse Voltage Rating

A primary factor is ensuring the diode has a peak inverse voltage (PIV) rating
well above the worst-case spikes expected from the inductive load when
interrupted. Typical relay coil voltages ranges from 12V to 240V. Allowing at
least a 2X margin is recommended.

2. Forward Current Rating

The diode needs to handle the full load current flowing when in its normal
conducting orientation without overheating. Consider both average and peak
forward current. Look for published surge current specs.

3. Switching Speed

Ultrafast diodes with short reverse recovery times are strongly preferred for
suppressing fast relay switch-off spikes most effectively. Standard or fast
options may still allow some initial flyback.

4. Temperature Range

The diode must perform across the full operating temperature band of the
system environment without loss of function. Look for operation from at least
-40°C to 100°C.

5. Packaging

Surface mount diode options occupy very little space on PCBs and allow
automated assembly. Leaded through-hole diodes work where needed too.
Consider heat sinking needs.

Now let’s examine some of the most suitable diode technology options to
deploy with relays for robust noise protection.

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Technical Options for Implementing Flyback Diodes

There are several viable technical routes for integrating flyback diodes into
relay driver circuits for control of electrical noise:

Discrete External Diodes

Standalone diodes wired in parallel across inductive loads are a simple and low
cost approach, provided proper electrical ratings are selected.

Ultrafast diodes like the 1N4148 excel due to very short <4ns reverse recovery
times. Other fast switching models using Schottky diode construction may also
suffice.

Small size SMD components work well for automated PCB assembly.

Discrete external ultrafast diode placed directly at relay

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Internal Suppression Diodes

Many standard electromechanical and solid state relay components have

internal suppression diodes integrated directly across the coil inputs for
convenience:

Built-in flyback diode inside relay module

This saves some wiring effort and parts cost. However the parameters of
internal diodes may not always be fully disclosed or suitable for all applications.
External diodes offer more flexibility if needed.

Relay Driver ICs

Specialized integrated circuits designed to control relays often also incorporate

flyback diodes internally:

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Single chip solution integrates control, drive and suppression functions

This provides a compact, self-contained solution when paired with the relay
itself. Convenient protection against electrical noise is included by design.

RC Snubber Networks

While less effective than diodes, an RC network connected across inductive

loads forms a low pass filter to suppress some moderate switch-off spikes. The
resistor dissipates energy as current continues through capacitor.

Appropriate component values must be calculated based on the inductance

and transient response behaviour. This adds complexity compared to simply
using a suitable diode.

Integrated Relay Modules

Complete integrated PCB assemblies are available which incorporate relay coils,
high current contacts, drive electronics and onboard noise suppression:

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Smart power relay module with integrated diode protection

These eliminate the need to select flyback components and simplify design
effort significantly. However costs may be higher than discrete
implementations.

Intelligent Control of Relays Can Further Reduce Noise

While flyback diodes largely address relay switch-off transients, additional

proactive design choices can further minimize disruptive electrical noise:

Gradual power ramp down — Rather than abruptly cutting all power to the
relay coil, gradually ramp down the drive current over ~1ms until it reaches
zero. This reduces severity of collapse of magnetic field and voltage spikes.

Delayed cut-off — Extend relay drive signal for ~10ms after switching
contacts transition before disabling coil. This allows transient to dissipate
before removal of drive current.

Snubber capacitor — Small capacitors can be installed along with diodes to

form low pass filter networks. Values from 0.1uF to 1uF often used. Dissipates
energy gradually. May allow smaller diodes.

Linear drive — Specialized relay driver ICs can modulate coil power linearly
instead of simple on/off. Allows gentle make/break ratcheting of magnetic
forces for quieter carry current switching.

Opto-isolated control — Fiber optic, digital isolator and optocoupler devices

enable electrical separation of low voltage control circuits from relay coil drive.
Prevents coupled transients.

So both appropriate flyback diodes as well snubbing components work

together with intelligent drive techniques to suppress electrical noise from
relay actuation.

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Example Circuits Implementing Flyback Diodes

To demonstrate practical application of flyback diodes for control relay noise,

below are two sample circuit implementations:

Standard Relay Drive

In this basic DC load switching design, an NPN bipolar transistor is used to

control a 12V standard electromechanical relay. An ultrafast signal diode
suppresses coil switch-off spike:

External fast diode suppresses relay noise

High Current Motor Control

For this 120VAC motor load application, a solid state relay allows
microcontroller interface. Fast recovery diode and RC snubber dissipate relay
turn-off transient:

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Snubber network filters SSR switching noise

So in both low and high power circuits, appropriate choice of flyback diodes
combined with other noise reduction methods enable clean relay control.

Conclusion

The effective application of flyback diodes across inductive loads like relay coils
provides critical suppression of dangerous voltage spikes and electrical noise
resulting from abrupt current interruption.

Careful flyback diode selection considering voltage, current and switching

parameters alongside techniques like snubbers and intelligent drive control
facilitates stable, reliable and safe system operation.

By preventing false signals, interference issues and premature component

failures from relay switching transients, flyback diodes constitute a simple and
inexpensive design element that is indispensable for controlling relays in
industrial equipment, automation systems and many other electronic products.

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Frequently Asked Questions

Q: Why are standard rectifier diodes unsuitable as flyback diodes

for relays?

A: Standard rectifier diodes have relatively long reverse recovery times,

allowing damaging initial voltage spikes through before they begin conducting.
Ultrafast signal diodes with faster switching are necessary to clamp transient
instantly.

Q: Is it always necessary to install flyback diodes externally even if

relay modules have internal ones?

A: Usually not required. Most quality electromechanical or solid state relay

modules integrate internal suppression diodes that sufficiently protect external
circuitry. But for very noise sensitive systems, adding another external diode
provides extra reliability.

Q: Can flyback diodes be used in AC relay circuits as well?

A: Yes, flyback diodes work with AC relays also but require a slightly different
configuration using back-to-back parallel diodes allowing each diode to
conduct in opposite polarity direction for full wave transient suppression.

Q: Instead of using a flyback diodes, can a resistor or zener diode

provide the suppression needed?

A: Resistors dissipate noise energy but allow higher remaining voltages that
may still cause issues. Zeners clamp voltages but must dissipate all transient
energy as heat, risking damage. Flyback diodes provide both voltage clamping
and current path restarting, handling inductive kickback safely.

Q: What happens if no flyback diode is used with a relay?

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A: Operation may seem normal initially but eventually sensitive components

will fail prematurely or exhibit functional issues like resetting, false activations,
or output signal corruption/interference due to relay switch-off electrical noise.
Critical protection against inductive spikes will be lacking.

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