Master Electronics Relay Guide 2018

ABOUT US EMR VS. SSR CHART SELECTING A RELAY

VOLUME 1

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RELAYS 101

SUPPLIERS INFO

RELAY GUIDE

Relays 101 Relay Fundamentals Relay Applications

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APPLICATIONS

FUNDAMENTALS

FEATURING

ABOUT US EMR VS. SSR CHART

WELCOME

TO THE MASTER ELECTRONICS

RELAY GUIDE

SELECTING A RELAY

YOUR GUIDE TO TODAY’S RELAY TECHNOLOGY SOLUTIONS FOR DESIGNERS AND PURCHASERS Master Electronics is excited to bring you our Relay Guide. Inside we give you a quick overview of what relays are, what they do in a product or system, what types of relays exist, and the solutions they can provide in some typical applications. Whether you’re in design or purchasing, you’ll find this up-to-date “short course” on relays to be useful, concise, and wellworth adding to your reference file.

SUPPLIERS INFO

We also include information on a wide array of essential relay products currently offered by some well-known industry manufacturers. Product line information is included from Crydom / Sensata, Schneider Electric, American Zettler, TE Connectivity, and Omron Electronic Components, along with information on benefits, specs, and applications. From power relays to solid state, from panel to PCB to rail mounts, you’ll find it all here.

RELAYS 101

As an authorized distributor for 56 different relay manufacturers, Master Electronics is uniquely qualified to offer you this information. If you find our Relay Guide valuable, we invite you to pass it along to your associates or project partners. You can download an easy to e-mail PDF of our Relay Guide on the Master Electronics website at MasterElectronics.com, or you can request additional printed copies from your Master Electronics sales associate.

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TABLE OF CONTENTS FEATURES

APPLICATIONS

FUNDAMENTALS

02 03 04 05 16 19 20 22 2

SUPPLIERS

Master Electronics Relay Guide About Master Electronics Master Electronics EMR vs. SSR Chart Steps To Selecting An Appropriate Relay Relays 101

06 08 10 12 14

Sensata / Crydom Omron Electronic Components Schneider Electric TE Connectivity American Zettler

Relay Line Card Relay Fundamentals Relay Applications

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ABOUT ABOUTUS US EMR VS. SSR CHART

ABOUT MASTER ELECTRONICS

SELECTING A RELAY

Master Electronics, headquartered in Santa Monica, CA, is a leading authorized distributor of electronic components, systems and sub-systems.

We are dedicated to stocking a wide breadth of part numbers to support the world-wide design and production needs of modern engineering and purchasing departments, like yours.

RELAYS 101

SUPPLIERS INFO

In business for more than 50 years, Master Electronics is a franchised distributor for over 300 world-class suppliers and stocks over 370,000 unique part numbers. Our 9 stocking locations throughout North America offer convenient local inventory and service for companies with industrial, military, medical, aerospace and consumer applications. Each office is staffed with a knowledgeable and service-driven sales force, to make sure you get exactly what you need.

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Our extensive product line and broad part number stock includes relays, connectors, power supplies, fans, switches, circuit protection devices, passive components, filters and much more. Plus, our worldclass brand availability includes products from companies like ebm-papst, Honeywell, ITT Cannon, Omron Electronic Components, Panasonic, TE Connectivity and many others. We make certain your creativity is not hindered by part sourcing.

HELPING MOVE IDEAS FROM ENGINEERING TO MARKET.

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APPLICATIONS

FUNDAMENTALS

MASTER ELECTRONICS.

ABOUT US FUNDAMENTALS

SSRs

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RELAYS 101

SUPPLIERS INFO

EMRs

SELECTING A RELAY

EMR EMR VS. VS. SSR CHART

ELECTROMECHANICAL VS. SOLID STATE RELAYS PROS

CONS

Lower initial cost vs. solid state

Higher control (coil) power consumption

Complete electrical isolation

Contact arcing can cause pitting & eventual open/short failure

Tolerates high current & voltage transients

Contacts can be affected by corrosion, oxidation or contaminates

Insensitive to EMI/RFI

Contact bounce possible due to shock & vibration

Higher open resistance (air gap)

Generates EMI/RFI

Lower closed resistance

Can be orientation sensitive

Available with many poles/circuits (up to 8 or more)

Can be affected by external magnetic fields

Many circuit configurations available

Subject to mechanical degradation over time (residual magnetism, armature flexing, spring stretching)

Multiple packaging & feature options

Potential higher overall cost over equipment life

Most typical failure mode is open

Can be noisy

Substantially longer life vs. mechanical

Higher initial cost vs. mechanical

Low control power consumption

Generate more heat vs. mechanical

Faster on/off cycling

Current rating may require derating based on ambient temperature

Allows very fine proportional output control

Voltage or current transients can damage or affect operation

No arcing (safer in hazardous environments)

Susceptible to EMI/RFI

No contact bounce

Lower off state resistance

Not orientation sensitive

Higher on state resistance

Switching not affected by shock & vibration

Most are single pole/circuit (some available with up to 4)

Not affected by external magnetic fields

Normally Closed/ON function available on a limited basis

Less electromechanical interference

Changeover form/circuit not supported

Silent operation

Most typical failure mode is Shorted/Closed

APPLICATIONS

Allows many functions in a single package Potentially lower overall cost over equipment life

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SSR

Identify mounting type:

Identify mounting type:

ABOUT US EMR VS. SSR CHART

EMR

Identify Required Load Current Rating:

Identify Required Load Current Rating:

a. Calculate Average Load current b. Calculate Surge (inrush) current

a. Calculate Average Load current b. Calculate Surge (inrush) current

Identify required circuit/switching arrangement: a. Number of poles/circuits to be switched b. Normally Open, Normally Closed or changover switching function Identify Required Control Voltage & Type a. AC or DC b. Control Voltage Range

Use above parameters to identify a relay matching maximum load voltage, maximum surge current, load type, control voltage, type & mounting requirements.

SUPPLIERS INFO

a. AC or DC b. Determine maximum voltage to be switched

Identify Required Control Voltage & Type: a. AC or DC b. Control Voltage Range

Identify Load Type

RELAYS 101

a. AC or DC b. Determine maximum voltage to be switched

Identify Required Load Voltage Rating & Type:

a. Inductive (Random Turn-on SSR) b. Resistive (Zero Crossing SSR)

Identify Type of SSR Required: a. Standard b. Special Application:

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Identify Required Load Voltage Rating & Type:

SELECTING A RELAY RELAY

a. Panel b. DIN Rail c. Plug-in d. PCB

a. Panel b. DIN Rail c. Plug-in d. PCB

FUNDAMENTALS

i. Phase Angle Control ii. Burst Fire Control iii. Soft/Start Capability Use above parameters to identify a relay matching maximum load voltage, maximum surge current, load type, control voltage, type & mounting requirements.

Determine the amount of heat to be dissipated & select suitable thermal management solution.

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APPLICATIONS

STEP 08

STEP 07

STEP 06

STEP 05

STEP 04

STEP 03

STEP 02

STEP 01

STEPS TO SELECTING A RELAY

ABOUT US EMR VS. SSR CHART

PRODUCT INFO WHAT IS A SOLID STATE RELAY/CONTACTOR?

SELECTING A RELAY

A Solid State Relay or Contactor (SSR or SSC) is an electronic component that switches Power (AC or DC current) to a load circuit and provides electrical isolation between an application’s control circuit and load circuit. It is a competitive technology to Electromechanical Relays (EMRs) and other switching technologies such as Mercury Displacement Relays (MDRs).

WHY USE SOLID STATE SWITCHING TECHNOLOGY?

Long Life Quiet Operation Minimum Electrical Noise Low Power Consumption

Shock & Vibration Resistant Ideal for Harsh Environments High Compatiblity with Control Systems Reduced Weight

Position Insensitive Fast Switching Magnetic Noise Immunity Reduce Energy Cost

SUPPLIERS INFO

SOLID STATE RELAYS & CONTACTORS APPLICATIONS Although there are literally thousands of individual uses for Solid State Relays and Contactors, most can be categorized into the following applications:

HEATING CONTROL

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RELAYS 101

This encompasses the largest segment of solid state relay users.

Applications include, but are not limited to: professional food equipment, plastic molding/extrusion machinery, HVAC&R and soldering equipment.

Benefits: Long life, no maintenance, safe product, easy to interface, as well as enabling temperature accuracy. Suitable for heaters, fans, blowers and valve control.

MOTION CONTROL Includes elevators, lifts, hoists, exercise equipment, conveyor systems, solar trackers, fans, solenoids and valve control.

Benefits: Endurance, shock & vibration resistance, Soft Start, reversing, no arcing, fast switching, long life, no maintenance, easy to interface, reduced parts count.

FUNDAMENTALS APPLICATIONS

POWER CONTROL Power applications cover switching of power supplies, transformers, regulators, inverters, converters, UPS systems, etc. Benefits: Easy to interface, no arcing, immune to magnetic noise, automated switching, low electrical noise, no maintenance, shock and vibration resistant.

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PCB Mount Solid State Relays PCB Mount solid state relays are mounted directly into PCB boards.

They are ideal in an application where a small, power-dense package is required.

Plug-In Solid State Relays Plug-in solid state relays are designed to install quickly and easily in industry standard relay sockets.

Proportional Control Relays Proportional Control solid state relays offer precise control of the power delivered to a resistive load.

ABOUT US • • • • • •

• • • •

Power Supply Controls Plastic Machinery Packaging equipment HVAC

• NOVA22 Series • SeriesOneDR • DRA Series

• • • • •

Medical Machinery Food Proccesing Machinery Power Supply Controls Cooking Equipment Vending Equipment

• CX Series • CMX Series • CN Series

• • • • •

Lab Testing Equipment Medical Machinery Food & Beverage Equipment Packaging Machinery Transportation Equipment

• LifePlus ED Series • CN Series

• • • • • •

Water Heaters Packaging Equipment Infrared Heaters Plastic Machinery Water Heaters Lighting Dimmers

• • • • • •

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SELECTING A RELAY

Series1 EL Series HDC Series GN Series CW Series HA & HD Series

SUPPLIERS INFO SUPPLIERS

DIN Rail Mount solid state relays are “ready-to-use” SSRs that are designed to fit on a standard 35mm wide symmetrical DIN Rail.

Medical Systems Solar Panels Water Heaters Commercial Ovens Telecom Equipment Transportation Equipment

RELAYS 101

DIN Rail Mount Solid State Relays

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Panel Mount solid state relays are desgined to easily mount on flat panels or heat sinks.

KEY PRODUCTS

FUNDAMENTALS

Panel Mount Solid State Relays

APPLICATIONS

PMP Series RPC Series PCV Series LPCV Series MCPC Series MCBC Series

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APPLICATIONS

PRODUCT LINE/DESCRIPTION

EMR VS. SSR CHART

PRODUCT INFO

ABOUT US

PRODUCT INFO

EMR VS. SSR CHART

For over 80 years, Omron Electronic Components has been a leading manufacturer and provider of advanced electronic components. Extensive product groups include relays, switches, connectors and a variety of sensors such as Facial Recognition, Seismic, Photomicrosensors, Environment Sensing, MEMS Flow, Pressure and Thermal Sensors. Omron Electronic Components is the Americas subsidiary of Omron Corporation, a $7 billion global leading supplier of electronics and control system components and services. Omron’s broad product offering can be found in applications for the communications, transportation, HVAC, appliance, industrial automation, consumer electronics, test and measurement, and gaming markets around the world.

SUPPLIERS INFO

SELECTING A RELAY

NEWEST RELAY RELEASES G3VM CR/FR MOSFET Relays DIP 8 Package High Capacity 3A (6A) /1.5A (3A) High Load Voltage (100V/200V) High Temperature +110° C

G3VM QR S-VSON MOSFET Relays Super Small Package S-VSON/(L) 1.3(H) x 1.45(W) x 2.0(L), High Ambient Temperature: -40 to +110° C High Switching Current and Low CxR Models

High Frequency Relay 8GHz Band G6K-2F-RF-V Insertion loss <= 3 dB at 8 GHz Miniaturized to 11.7 × 7.9 × 7.1 mm (L × W × H) Low coil power consumption 100 mW

G5RL PCB Power Relay High-Inrush model available (up to 100 A) Low Noise models available (Approx.

10 to 20 dB less sound pressure than standard G5RL-Series Relays) TV8 Rating models available (TV8 for UL standard), 117A Inrush

RELAYS 101

PRODUCT LINE/DESCRIPTION Low Signal Relays High Reliability Miniature

APPLICATIONS

FUNDAMENTALS

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Relays for low level current switching, up to 2A; PCB and SMT Terminations, Low Power Consumption, Latching models available

G3VM MOSFET Relays Wide product selection in DIP, SOP, SSOP, USOP,VSON and SVSON packages with low ON-resistance, low Off-state capacitance and high Dielectric Strength

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APPLICATIONS

KEY PRODUCTS

• • • • •

G6K • Small DPDT Relay • 1A@30VDC • 2A(carry) • 0.3A@125VAC G6S • DPDT Relay • 2A@30VDC • 0.5A@125VAC G6J-Y • Ultra-small • Slim DPDT Relay • 0.3A@125VAC • 1A@30VDC

Telecom & Datacom Test & Measurement HVAC Security Devices Industrial Machinery

• Test & Measurement Devices • Security Systems • Broadband Systems • Industrial Equipment • Battery Powered Equipment • Amusement Machines

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G3VM • Genaral Purpose • Ultrasensitive • Ultra Small • Current-Limiting • 1 form A • 1B and 1A1B contacts • High Voltage & High Dielectric strength models

Automotive Relays Automotive Relays in PCB and Plug-in options 3OHDVH FRQæUP 2PURQ 6DIHW\ 3UHFDXWLRQV IRU DOO DXWRPRWLYH UHOD\V

High Frequency Relays Miniature DPDT High Frequency Relays for Differential Transmission

ABOUT US EV Charger Fuel Cell HEV/EV Car Home Energy Storage System Capacitors (Relay for High Voltage Interruption) • Electric Forklift

G9EJ-1-E • 15A@400VDC • SPST-NO • PCB/ Tab#250 • Small • Lightweight G9EN • 60A@400VDC • SPST-NO • Screw Terminals • Small

• • • • • •

Agricultural Vehicles Construction Vehicles Recreational Vehicles Passenger Cars Trucks Buses

G8HE • Plug-in Micro ISO • SPST/SPDT • Unsealed • 120A switching • 35A carry G8N • Micro-Mini PCB Relay • Sealed/Flux Protection • SPDT • Switching 25A • 5A carry

• • • • •

IC Testers Network Analyzers Oscilloscopes Signal Generators Mobile Phone Base Stations

G6K-2F-RF-V • 8GHz type G6K-2F-RF-T • 3GHz type G6K-2F-RF/2P-RF • 1GHz, SMD and THT

• • • • •

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SELECTING A RELAY SUPPLIERS INFO SUPPLIERS

Interrupts high voltage/current loads; extinction of magnetic arc by high-efficiency magnetic circuit. Superior inrush-withstand performance and long-life

G2RL • SPDT & DPDT • 8~16A@250VAC G5Q • SPDT • 10A@125VAC • New Models: 300K ops Long Life 40A Inrush G5NB • Slim SPST • Long Life • 7A@250VAC • 200mW coil

Building Automation Household Appliances Industrial Machinery Energy Systems HVAC Equipment Lighting Systems

RELAYS 101

DC Power Relays

• • • • • •

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High switching capacity, unsealed, flux protection and sealed options.

Contacts 1 form A, 1C, 1A1B, 2A and 2C. Long Life and Glow Wire models

KEY PRODUCTS

FUNDAMENTALS

Power PCB Relays

APPLICATIONS

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APPLICATIONS

PRODUCT LINE/DESCRIPTION

EMR VS. SSR CHART

PRODUCT INFO

ABOUT US EMR VS. SSR CHART

PRODUCT INFO PRODUCT LINE/DESCRIPTION General Purpose Relays

SELECTING A RELAY

• Can handle current loads from 10 mA to 15 A • Socket, panel & DIN mount options • Multiple features & contact configurations available • Optional protection, mounting & identification accessories

Power Relays

SUPPLIERS INFO

• Rated up to 50 A • Socket compatible models available • Semi-sealed versions available • Blowout magnet options for high DC voltage switching • Feature-rich covers, mounting options & accessories to suit a multitude of applications

RELAYS 101

Solid State Relays

APPLICATIONS

FUNDAMENTALS

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• 100% solid state design • Modern appearance & advanced technology • High cycling rates • High breaking capacities (up to 125 A) • A wide range of input voltages • Industry first design (861 & 861H series) • Various styles to fit multiple applications

Time Delay & Sensor Relays • Multi-function up to ten • Wide voltage range from 12 to 240 V • Flexible timing range 100 ms to 10 days • DIN or Panel mounting styles • Conform to international standards including UL, CSA, RoHS & CE

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APPLICATIONS

KEY PRODUCTS

• Automation Control Panels • Packaging Machinery • Processing Machinery • Lighting Controls • Power Supplies • Industrial Appliances • Motor/Pump Controls • Oil & Gas

• 781, 782, 783 & 784 Series Plug-In Relays • 750 Series Octal Plug-In Relays • 788 Series Plug-In Relays • 792 Series Plug-In Relays • 782H Series Hermetically Sealed Relays • 750H Series Octal Hermetically Sealed Relays

• • • • • •

• 199 Open Frame Power Relays • 725 Series Power Relays • 389F Series Power Relays • 300 Series Power Relays • 92 Series Power Relays • 9A Series Power Relays

Automation Panels Processing Equipment Packaging Machinery Lighting Controls Power Supplies Motor/Pump Controls

• Industrial Heater Controls • Process & Material Handling • Lighting Controls • Medical Equipment • Automatic Door Controls • Oil & Gas

• 861 Series Relays • 861H Series UL Class I Div 2 Relays • SSR DIN Series Relays • 6000 Series Relays • 70S2 Series Relays

• • • • •

• 820 Time Delay Relays • 831 Voltage Sensing Relays • 841 Current Sensing Relays • TDR782, TDRPRO & Time Delay Relays

Automation Panels Packaging Machinery Lighting Control Material Handling Motor/Pump Control

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PCB & Reed Relays • Space-saving package design • Single & double pole switching • Ratings range from 0.25 to 20 A • Fully sealed for wash-down processes • Wave solderable

ABOUT US

APPLICATIONS • • • • •

Automotive Lighting Controls Electronics & Communication Security Automated Test Equipment (ATE) • Medical Equipment

KEY PRODUCTS • 117SIP, 107DIP, 171DIP & 172DIP Series Reed Relays • 276, & 976 Series PCB Relays

SELECTING A RELAY

PRODUCT LINE/DESCRIPTION

EMR VS. SSR CHART

PRODUCT INFO

SUPPLIERS INFO SUPPLIERS

INTERACTIVE ECATALOGS

RELAYS 101

• Built-in search tool for each individual catalog • Catalog part numbers are linked to respective online product pages • Add notes to catalog pages • Print or export single or multiple pages in PDF format • Email links to ecatalog pages and share via social media

INTERACTIVE WEB TOOLS

INTERACTIVE WEB TOOLS • • • •

2D line drawings and 3D modeling files available Download to desktop or send via email Import files into an open CAD/Modeling pane Available in most major 2D and 3D drafting platforms

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APPLICATIONS

FUNDAMENTALS

LINE CARD

• Available for timers, latching relays, PCB relays and sockets • Learn about timing functions, how to wire latching relays, the differences between PCB and reed relays and how to choose a socket and accessories

ABOUT US EMR VS. SSR CHART

PRODUCT INFO

SUPPLIERS INFO

SELECTING A RELAY

PRODUCT CATEGORIES & FEATURED PRODUCTS: PANEL/PLUG IN RELAYS KRPA/MT • Industry standard octal/ undecal type termination for quick installation • DC and AC Coils • Mechanical indicator, indicator lamp and push-to-test options

KUP/KUMP/KUIP • Wide selection of termination and mounting styles • Broad range of contact forms • PC terminals available • Push to test button and indicator lamps

RM8/C/D • Power relay with push-on and solder terminals • Various mounting options • Class B coil insulation

K10 • Mounting options include socket, PCB, Top flange • DC and AC Coils • LED versions available

PT/KH • Sensitive coil • Low height 29/33mm • Cadmium-free contacts • Mechanical indicator • Manual test tab, optionally lockable optional LED, protection diode

R10 • Broad range of coil options provide sensitivity ranging from 25 to 750mW • Various contacts switch from dry circuit to 7.5A • Many mounting and termination options

APPLICATIONS

FUNDAMENTALS

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RELAYS 101

PRODUCT CATEGORIES & FEATURED PRODUCTS: LOW POWER PCB RELAYS

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OMI/OMIH/OMIT • Meet 5kV dielectric voltage • 10kV surge voltage between coil and contacts • Version with 1 form A, 1 NO contact TV-5 rating (OMIT)

RT • Sensitive DC and AC coil • Bistable version • 5kV/10mm coil-contact • Reinforced insulation • Ambient temperature 85°C

RYII • 5kV/8mm coil-contact • Reinforced insulation • Low height 12.3mm • Pinnings 3.2 and 5mm

MSR/T75 • High inrush currents with AgSnO contacts • 4kV/8mm coil-contact • Reinforced insulation

SNR • Only 5mm wide • Cadmium-free contacts • Sensitive coil 170mW • 4kV coil-contact • 6/8mm creepage/clearance • Protection class II

RE/REL • Sensitive coil 200mW • 4kV coil-contact (REL) • PCB area 200mm2

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ABOUT US EMR VS. SSR CHART

PRODUCT INFO

PCN OJ/OJE/T77 • Only 5mm wide slim type, • Miniature size permitting high density • Meet 4kV dielectric spacing between coil and contacts • Sensitive coil 120mW (OJ/OJT) • Cadmium free contacts • Sensitive coil 200mW type available • Meet UL TV-5 ratings (OJT)

SR2M • 2 pole relay with force guided contacts according to EN 50205 • Reinforced insulation between poles

SR4 D/M • 4 pole relay with force guided contacts according to EN 50205 • Compact design, space efficient

SUPPLIERS INFO

SR6 • 4/6 pole relay with force guided contacts according to EN 50205 • Reinforced insulation between all contacts

T92 • Switching capacity 7500VA • DC or AC coil • 4kV/8mm coil-contact • PCB or QC connections or chassis mount

PCF PCFN Solar • QC terminal for load (PCF • Specially designed to meet only) the requirements for the • Height 26.5mm solar inverter industry • Meet 4kV dielectric • Contact gap >1.5mm voltage between coil and • 200mW hold power contact • Ambient temperature 85°C

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T9S • Specially designed to meet the requirements for the solar inverter industry • Contact gap >1.5mm • 350mW hold power • Product in accordance to IEC 60335-1 • EN 61095: AC7 at 85°C

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EF • Low profile max. 20.0mm • QC terminals for load • Meet 4kV dielectric voltage between coil and contact

FUNDAMENTALS

T9A/T9E/T90 • High breaking capacity • PCB and QC connections and chassis mount version • UL-class F as standard • Ambient temperature 85°C • Open version available

RELAYS 101

PRODUCT CATEGORIES & FEATURED PRODUCTS: PCB HIGH POWER, METERING AND SOLAR RELAYS

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APPLICATIONS

RZ • Sensitive coil 400mW • 5kV/10mm coil-contact • Reinforced insulation • Ambient temperature 85 or 105°C • Height 15.7mm • In acc. to IEC 60335-1

SELECTING A RELAY

PRODUCT CATEGORIES & FEATURED PRODUCTS: LOW POWER PCB RELAYS AND FORCE GUIDED RELAYS

ABOUT US EMR VS. SSR CHART

PRODUCT INFO POWER RELAYS: HVAC/R AND MOTOR CONTROL

SELECTING A RELAY

SWITCHING CAPACITY TO 50A • Single and multiple pole configurations • Universal application use • Panel mount and PCB • AC and DC Coils • Motor start potential relays AZ2150, AZ2280, AZ2800

GENERAL PURPOSE

SUPPLIERS INFO

SWITCHING CAPACITY TO 20A • High temperature contact ratings • Extended life UL contact ratings • Common in appliance controls • Low profile and thin packages • Class B and Class F UL insulation systems AZ943, AZ7709, AZ743, AZ9375

RELAYS 101

AUTOMOTIVE

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SWITCHING CAPACITY TO 80A • Mini ISO, micro ISO, 280 styles • PCB and plug-in • Brackets, shrouds, sealed types • Single and dual package PCB relays • Open and enclosed types AZ9731, AZ977, AZ980, AZ9891J

APPLICATIONS

FUNDAMENTALS

INDUSTRIAL SWITCHING CAPACITY TO 50A • Contact configurations up to 4 poles • AC and DC Coils • Panel mount with blowout magnets • Ice cubes with bracket, PCB, or plug in • DIN rail sockets and accessories AZPRD, AZKUP, AZ1651, AZ6991

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ABOUT US EMR VS. SSR CHART

PRODUCT INFO ALTERNATIVE ENERGY: SOLAR INVERTERS AND ELECTRIC VEHICLE CHARGING

SELECTING A RELAY

SWITCHING CAPACITY TO 100A • Single and multiple pole configurations • Contact gaps to 3.6mm • Low holding voltage required • Switching voltages to 690VAC, 1000VDC • Reinforced insulation (EN60730-1, 60335-1) AZSR131, AZ2150W, AZSR190, AZ2704, AZSR250

LATCHING, LIGHTING, AND ENERGY MANAGEMENT RELAYS

SUPPLIERS INFO

SWITCHING CAPACITY TO 120A • Switching voltages to 480VAC • Ultra-low coil power types • Latching and monostable options • UL20, IoT, photocontrols • Smart metering relays (meet UC3) AZ9405, AZ576, AZ7555, AZ2505

RELAYS 101

TELECOM

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SWITCHING CAPACITY TO 5A • Contact arrangements to 6 poles • Industry standard footprints • Latching and non-latching • SMT and THT mounting • Multiple coil resistance options AZ826, AZ8462, AZ8521, AZ420

SWITCHING CAPACITY TO 90A • Contact configurations up to 4 poles • Interlock, aux contacts, or micro switch • QCT, box lugs, or hex head screws • Extended life cycles at 70oC • 100kA SCCR @600VAC XMC0

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APPLICATIONS

FUNDAMENTALS

DEFINITE PURPOSE CONTACTORS

ABOUT US EMR VS. SSR CHART

What They Are

SELECTING A RELAY

RELAYS 101 In a very basic sense, a relay is simply a binary actuator.

At any point in time it has one of two steady states – either energized and latched, or de-energized and unlatched. For the uninitiated, that essentially means either ON or OFF. In fact, some of the very first computers were built with a large collection of relays to execute Boolean (logic) gates.

...AND THEN SOME!

RELAYS 101

SUPPLIERS INFO

From an engineering and design standpoint, basic relays are elegantly simple. They contain an electromagnet, some electrical contacts, an armature that can be controlled by a magnetic field, and a spring. The spring holds the armature in place. The electromagnet attracts the armature when a current is applied. This set-up allows a relay to control a highcurrent electrical load with a low-current electrical signal. This quality facilitates their use to control power in a wide variety of devices and systems.

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When a relay is normally open (NO), there is an open contact and the relay is not energized. When the contacts are normally closed (NC), there is a closed contact when the relay is not energized. Application of electrical current changes their state.

APPLICATIONS

FUNDAMENTALS

In devices that consume a lot of power, and that would normally require an extensive amount of wire, a relay can be used with a pair of low-power wires to control the ON/OFF electrical flow. In fact, since the circuit powering the coil is physically separated from the circuit powering the device, relays are commonly used where it’s impossible to have a direct connection between the control circuit and the output device, either because of risk to the equipment or the safety of the operator.

Relays are widely used to switch devices like heating elements, starter coils, alarms, pilot lights and motors. High power relays are used in electric vehicles and other transportation platforms. Relays can also control the maximum current and voltage that can go through the armature and contacts, the number of armatures used, the number of contacts used, and whether the contact is normally open or closed.

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ABOUT US

What Kind of Relays are Available Today ?

EMR VS. SSR CHART

There are generally two broad types of relays: Electromechanical Relays (EMR) and Solid State Relays (SSR). Each of these types of relays have several subsets to fit particular applications.

EMRs work via the physical movement of internal components and are open or closed by a magnetic force when a current is applied. EMR types include the following:

•

SELECTING A RELAY

•

SUPPLIERS INFO

•

General Purpose Relays are simply electromechanical switches that operate with AC or DC current, usually 12V – 230V, and control currents from 2 amps to 30 amps. Their benefits include low-cost, ease of replacement and wide range of configurations.

Machine Control Relays are heavy duty devices used to control starters and large industrial components.

While more expensive than general purpose relays, they are more durable and they can easily be combined with accessories to expand their functionality to include timing, latching control and transient noise suppression.

Latching Relays have two states. They are set either ON or reset OFF by the input of voltage. The relay maintains this set or re-set condition until it receives the next inverting voltage signal.

Reed Relays are so-named because they consist of two reeds, hermetically sealed in glass to make them immune to contaminants, humidity or fumes. They are normally small, compact and fast operating with most often a single Normally Open (NO) contact. In operation, the ends of the contact are closed by a magnetic force. Reed Relays, easily driven by low power control circuits, are often used to control industrial components like solenoids and contactors which switch high current/power loads.

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SSRs do not incorporate physical contacts and their switching is totally electronic. They consist of an input circuit, a control circuit and an output circuit. Unlike EMRs, where the magnetic coil accomplishes the coupling between the input and output circuits, SSRs do this via the control circuit, which is activated when a voltage higher than the specified pickup voltage is applied to the control input. The relay is deactivated when the voltage applied is less than the specified dropout voltage. Common SSR voltage ranges are 3VDC to 32VDC, making them useful for electronic circuits.

The types of SSRs include the following:

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Zero-Switching Relays work by turning ON the load when the control voltage is applied and the voltage of the load is close to zero. They turn OFF the load when the control voltage is removed.

Instant ON Relays turn the load ON as soon as the pickup voltage is applied.

Peak Switching Relays turn the load ON when the control voltage is applied and the voltage of the load is at its peak. They turn the load OFF when the control voltage is removed and the current in the load is close to zero.

Analog Switching Relays have a circuit that controls the amount of output voltage as a function of the input voltage. This allows an infinite number of possible output voltages within the rated range of the relay.

These relays turn OFF when the control voltage is removed and the load current is near zero.

Optically Coupled Relays accomplish current switching in response to the ON or OFF state of a light source (usually an LED). They are faster than electromagnetic relays and provide isolation between the control & power circuits.

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Relay Ratings and Configuration

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Relay ratings address their ability to handle power. Ratings are usually given in terms of amperes and amp levels must be as large as the rating of the target device.

Configuration is dependent on the number of things the relay can control simultaneously. With one input and one output it is a simple on/off switch, or single throw. For two outputs, there are two throws. Pole and throw information is designated like this:

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Relay contacts are either normally open (NO) or normally closed (NC), depending on the state that exists when no power is applied.

Common Relay Applications

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As you can see, a relay is a rather simple device that performs a very useful function, leading to a diversity of uses across products and markets. All relays operate in the same basic way, but a range of types exist to match selected applications, mountings and environments.

RELAYS 101

Modern relays are used in areas ranging from consumer electronics and home appliances to autos and transportation. They are employed in process control systems, from small to large. They function as motor controls and motor protection devices. They help control systems from as small as automatic garage door openers to large electric power systems. They have aerospace, defense and marine applications as well as in emergency standby power systems.

It is difficult to imagine a modern product or system in which power is being directed or controlled that doesn’t use some type of relay.

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Changes in the Technology of Relays The application of semiconductor technology in the relay sector has been the biggest driver of change over the past 10 years, utilizing smart power solutions in SSRs to reliably deliver high current. Digital technology has also allowed many more relay functions to be incorporated in a single hardware package. Plus, the spread of LED technology has led to improvements in optically coupled small signal solutions.

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Single pole, single throw: SPST Double pole, double throw: DPDT Three pole, double throw: 3PDT Single pole, three throw: SP3T

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ABB Agastat/TE Aleph Altech Corp American Zettler Amperite Automatic Timing & Controls (NCC) Axicom/TE

Hartmann/TE Hasco Honeywell HongFa

Panasonic Electric Works Potter & Brumfield/TE

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Deltrol Controls

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F Fuji Electric Fujitsu Components

G Gentron Gordos Guardian Electric

L Lovato Electric

M MEC Relays Midtex/TE

N NEC Relays NTE

O OEG/TE Omron Electronics Omron Industrial

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Kilovac/TE

T Teledyne Coaxial Products Teledyne Military SSRs Teledyne Relays

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IDEC Corp Ixys ICs (Clare)

Schneider Electric Schrack/TE Sensata / Crydom Siemens Energy Solid State Optronics Song Chuan Stancor Standex Struthers Dunn Symcom

W Wago Weidmuller White-Rodgers Wieland Wilmar/TE World Products

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Carlo Gavazzi CII Technology/TE Coto Technology Curtis Instruments (Albright) Cynergy3

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MASTER HAS YOUR RELAYS, CONTACTORS, SOCKETS/BASES, MATING CONNECTORS AND TERMINALS, DIN RAIL, AND MORE!

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RELAY FUNDAMENTALS

EMR VS. SSR CHART

FROM MECHANICAL TO SOLID STATE

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In today’s smart phone age, where palm-based computer power expands on a daily basis, the idea of a relay can be decidedly “old school”. Perhaps because relays were invented in 1835, most modern engineers may view them as clunky devices used in early phone systems, elevators, or rudimentary computers in the pre-transistor era.

Truth is, the relay as a useful product has held up remarkably well. Relays remain valuable commodities in situations where complete electrical isolation is needed between the primary switching signal and the signal being switched.

Their robust quality can handle high-current and voltage transients that would destroy even the most robust silicon transistor. And the limitless variations in their packaging, connectivity and features insure their use in countless modern electrical and electronic systems.

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Working Basics

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An elementary electromagnetic relay (Figure 1) contains two fixed-position contacts. One implements a closed-circuit connection between it and the armature (containing two movable-position contacts). The other fixed-position contact normally creates an open-circuit no connection. A spring, or gravity in some designs, holds the armature in its default position. Passing current through the coil creates a magnetic field in the iron core within it, pulling the armature closer and breaking the normally closed connection to one of the contacts and making the normally open connection to the other.

It is usually desirable to have rapid relay-switching speed to minimize injected switched-signal noise and to suppress armature-to-contact arcing. In a DC-based relay configuration, either a diode or a resistor/ capacitor series pair also commonly connects to the coil in order to dissipate voltage spikes caused by collapse of the magnetic field. AC-based relays sometimes include small copper rings crimped to the end of the coil to generate tiny out-of-phase current that increases the minimum armature pull.

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Figure 1: The functions of traditional mechanical relays are easy to understand, but they’re fraught with innumerable potential failure mechanisms.

Alternative Set-Ups The constant application of source current and/or voltage necessary to maintain a conventional relay’s switch function may present a design problem. To solve this, a latching relay may be used. A latching relay is bi-stable, with two relaxed states. When the applied current is removed, a latching relay remains in its last state, even thru a power failure. The most common means of implementing the latching function include:

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A ratchet and cam mechanism operated by a solenoid. The first pulse turns the relay on and the next turns it off.

Two opposing coils with a spring or permanent magnet to hold the armature and contacts in position. A pulse to one coil turns the relay on and a pulse to the other coil turns it off.

A remanent core requiring opposite-polarity pulses to turn the relay on and off.

Instead of leveraging an intermediary armature, magnetic material contacts are used in some designs. These move toward or away from each other in the presence of an applied magnetic field. Also, in order to suppress the corrosive effects of a conventional atmosphere, some relay designs place the contacts in a tube under vacuum, or containing an inert gas (reed relay), or in a liquid (mercury-wetted relay).

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Solid-State Relays While robust in design and function, traditional mechanical relays can be subject to life-limiting effects due to the nature of their operation, including contact arcing, residual permanent magnetism, contact bounce, and noise. The solid-state relay (SSR), because of its inherent design, is able to address many of these mechanical shortcomings, but has its own trade-offs to consider.

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SSRs are switched electronically and, like an electromechanical relay, can control high-current devices with a lowcurrent signal. Unlike mechanical relays, however, SSRs have no moving parts, turn on and off faster, produce less noise (EMI), and are less prone to the effects of physical vibration. They are, however, more expensive than mechanical relays, will dissipate more heat, and can be affected by voltage transients. Complete electrical isolation between the switching and switched signals is also not feasible with conventional SSRs. It can be achieved, if necessary, through an intermediary optoisolator, adding some cost and design complexity.

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Designers must also keep in mind the voltage drop across the source-to-drain junction of a transistor. This will impedance-alter the characteristics of the signal being switched and act as a current limiter on the peak capabilities of the SSR. If a latching (bistable) function is required in an SSR, a thyristor (siliconcontrolled rectifier) commonly is used instead of a transistor (Figure 2).

Figure 2: A thyristor (versus a conventional transistor) enables a solid-state relay to mimic the bistable A thyristor is simply a “pair of a pair” of coupled function of its mechanical latching-relay forebear. bipolar transistors. It consists of 4 layers of alternating p and n-type material, meaning there are 3 p-n junctions. The three terminals are called anode, cathode and gate. A thyristor acts as a bistable switch, conducting current when the gate receives a suitable current trigger.

With the anode at a positive voltage potential with respect to the cathode, and no applied gate voltage, there is no anode-to-cathode conduction. A further increase in the voltage potential, however, results in avalanche breakdown of one of the junctions, transitioning the thyristor to its conductive “ON” state. This transition will occur at a much lower anode-to-cathode voltage if a pulse gate voltage (acting as the switching signal) is applied. Past this point, conduction will continue until either the anode-to-cathode voltage potential or current flow is removed (or sufficiently lowered), or further gate switching signal application is unnecessary.

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SIMPLE SOLUTIONS FOR CURRENT AND VOLTAGE SWITCHING APPLICATIONS

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Deep into the digital age, the need to safely control large currents and voltages remains at the top of many engineering team to-do lists. The ability of relays to fill this key function across many applications rests on their simplicity, reliability, and life span. A list of potential specific applications could run hundreds of pages long, but here are a few broad functions that employ relays:

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RELAYS 101

In short, whenever and wherever a current must be switched, either from a distance or with a degree of safety, a relay can provide the solution.

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In the classical electromechanical relay (EMR), current flow through a coil induces a magnetic field that impels an armature to open or close contacts. While EMRs feature high breakdown voltage, no current leakage, and true galvanic isolation across open contacts, they do have a relatively short lifespan due to mechanical wear. Although EMRs remain the component of choice for applications operating at very high voltage or current levels, their utility in many low-voltage analog and digital designs is limited due to their relatively slow response time, reliability issues, physical size, and sensitivity to shock and vibration.

By eliminating the physical contacts of EMRs, solid-state relays (SSR) offer significantly higher reliability and lifespan than EMRs. Photo-coupled SSRs are based on conventional semiconductor switching elements such as thyristors, triacs, transistors, and diodes. They use optoelectronic components to isolate input and output (Figure 1). The result is a device that is compatible with digital logic and capable of much higher switching speeds and greater resistance to harsh operating environments than EMRs. On the other hand, SSRs exhibit small but significant leakage in the off state as well as higher output resistance than EMRs.

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Automation controls (electro hydraulics & pneumatics) Motor control Protective circuitry Industrial machinery Automotive, truck, bus, off-road & rail Energy & utilities Intelligent buildings Communications & wireless equipment Appliances Data centers Defense, military & aerospace equipment Oil, gas & marine equipment.

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Figure 1: A typical photo-coupled solid-state relay uses LEDs to isolate input from switched output.

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The flexibility and ease-of-use of SSRs allows relatively simple solutions in many applications. In the classic application, an SSR simply opens or closes a circuit supplying power to a load, such as a room heater (Figure 3). In practice, heaters built from some materials exhibit temperature-dependent load resistance. Thus care must be taken to prevent overcurrent in the SSR with the use of current limiting protection across the SSR.

Figure 2. A shunt resistor can prevent logic driver leakage current from inadvertent switching an SSR. VRXUFH DYDJR WHFKQRORJLHV

Figure 3: A typical application of SSRs involves switching power to a resistive load such as a room heater based on sensor input or logic functions.

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a.

RELAYS 101

SSRs are often an ideal, low-cost, safe solution for many motor-driven applications. For a reversible motor, a pair of SSRs could be used to drive the motor in forward and reverse directions (Figure 4a). To eliminate the possibility of switching both SSRs on simultaneously (a result that could overheat the motor) the SSRs could be driven with control signals that insert a delay in switching direction (Figure 4b). In practice, an SSR-based motor driver design would require SSRs with sufficient ability to withstand the large inrush currents encountered during motor startup, as well as suitable overvoltage protection to handle the back EMF generated by the motor when the SSR is turned off.

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Figure 4: a simple reversible motor solution (a) uses a pair of SSRs to drive the motor in forward and reverse directions, using a delay to ensure safe operation (b).

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APPLICATIONS

SSRs require very low drive currents to turn on, a characteristic that can result in unintended switching from leakage current in digital drivers. In this case (Figure 2) a shunt resistor placed in parallel with the SSR will ensure the gate leakage current will not turn on the LED and cause the SSR to switch. Assuming a logic gate has leakage current IOH driving into an SSR with a turn-on voltage Vf, a suitable shunt resistor RX‫ޒ‬VF/IOH would suffice to prevent inadvertent switching. For an SSR with an LED on drive current If, a suitable LED current setting resistor then becomes Rf=(VCC-VOL-Vf)/If.

EMR VS. SSR CHART

SSRs are current-controlled devices, requiring a specified forward current, Vf, for turn on. For operation from a voltage source VCC, an SSR with forward drop voltage Vf would then require a current limiting resistor Rf £ (VCC-Vf) If, using appropriate Vf and If values taken from curves of temperature-dependent performance provided in SSR datasheets.

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SELECTING A RELAY EMR VS. SSR CHART

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