Relays

basic information
Function of the relay ................................................................ 2
Main parts of the relay ............................................................ 2

Types of relays ....................................................................... 3

Terminology .......................................................................... 7

Coil operating voltage range ..................................................... 8

Coils - overvoltage protection .................................................... 8

Switching section: main diagrams and mechanical solutions ......... 10

Contacts and shapes of contacts ............................................ 11

Contact materials ................................................................. 13

Electric life of relays .............................................................. 16

Switching at alternating and direct current ................................ 17

Arc breaking ........................................................................ 17

Suppressing circuits ............................................................. 18

Special loads ....................................................................... 19

Switching time and contact bounce .......................................... 20

Sinusoidal vibrations ............................................................. 21

Current surges .................................................................... 21

Hermetic relays - soldering and cleaning ................................... 22

Types of relay terminals ......................................................... 24

International standards ......................................................... 25

According to USASI (United States of America Standards

Institute) a relay may be defined as an electrically controlled
device which opens and closes an electrical circuit in order
to affect the operation of other devices in the same or another
circuit. Relays are a significant element in the contemporary
industrial processes.

Dozens of milliards of relays operate nowadays in the world

as an interface between control circuits and electrical load.
The technological development has brought miniaturization
of mono- and bi-stable relays which need a low or even
no supply voltage to carry a high power through the contacts.

Relpol S.A. - 60 years of experience in production

of highest-quality relays.
 Relays
basic information

Function of the relay

The relay performs two crucial tasks: There are numerous applications of relays. Whenever satisfac-
1. Galvanic separation (isolation) of the control section and tory operation is needed in electronic and electromechanical
switching section. conditions, a relay is necessary, e.g. for control equipment,
2. Switching of high-power loads with high voltage and/or time relays, temperature control, etc.
current of high intensity at low energy consumption (low
vol­tage / low current intensity) even at low electrical signals.

Main parts of the relay

The electromechanical relay consists of an electromagnetic

switch and an electric one.

The former is the control section, and the latter is the switching
section which is directly connected to the electrical load.

The electromagnet transforms the electrical current into a

mag­netic stream that generates the force which moves the
switching part.

Electromagnet

Fig. 1. Classic electromagnet unit Fig. 2. Classic design of a relay

Armature Contacts Anti-dust cover

Coil

Yoke
Magnetic core
Contact terminals Coil terminals

Fig. 1 shows a classic electromagnet unit which consists of Additional parts:

four basic parts: - Fixed and movable contact springs.
The coil which consists of one or more windings of a copper - Contacts.
wire that is usually wound around a spool made of insulating - Pusher.
material. - Mounting terminals and coil terminals.
Ferromagnetic core. - Contact plate.
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Ferromagnetic yoke. - Anti-dust cover.

Movable ferromagnetic armature.

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 Relays
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Switching section
A classic arrangement of the switching section refers to a Fig. 3. Switching section of a relay
diagram of one changeover contact. It has been used in the
explanation below as it is a basic diagram referred to by all
other diagrams. NC contact
spring
Fig. 3 shows the switching section of a relay with one chan-
geover contact.
Movable Pusher
The figure presents the following parts: contact
- fixed normally closed (NC) contact unit, spring
- movable contact unit,
- fixed normally open (NO) contact unit,
- pusher, Contact plate
- contact plate, NO contact
spring
- soldering terminals.

Soldering
terminals

Types of relays

There are two kinds of the device, i.e. electromechanical relay and solid-state relay (SSR).

Electromagnetic and solid-state (SSR) relays

Operation of solid-state relays is very similar to that of electro- is generated when input voltage is applied to the coil. When
magnetic relays - it consists in switching the load circuit, which the supply voltage is interrupted, the return spring pushes the
is controlled with a low voltage signal of an insulated input contacts away from each other, i.e. opens the contacts and
circuit. In an electromagnetic relay, the electromagnetic force disconnetcts the power circuit.
which moves the yoke and causes switching of the contacts

Contact
Input Output
Return Coil
spring

Electromagnetic force

Solid-state relays use an opto-isolator to disconnect the The input current flows through a light-emitting diode which
input and output circuits. The opto-isolator changes electrical is usually made of gallium arsenide and it emits radiation in
signal to optic ones and transfers them through the distance infrared. The diode illuminates the photovoltaic cell which
which is a galvanic insulation between the input and output generates voltage to control the output element.
22.02.2018

sections. SSR’s are electronic devices which do not have any

movable parts, and the switching elements are thyristors, triacs
or transistors.

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 Relays
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In the opto-isolator, a photodiode, photo-transistor or a photo- The opto-isolator carries both direct-current signals and alter-
-thyristor may be be the photodetector. nating-current ones (analog and digital signals).

Control Power
Input Output input output

Light

Advantages of solid-state relays: As compared to solid-state relays, electromagnetic relays

1. Absence of movable parts due to which their operation is bear the stamp of negligible small voltage drop (the contact
completely noiseless, which is of high importance in dwelling resistance in switching state is on the average about 10 mΩ),
rooms, offices, etc. and zero leakage current, they are also highly resistant to
2. There is no electric arc in the course of switching opera- overvoltage. Due to the mechanical system of contacts and
tion which takes place inside the semiconductor material, their wear and tear, their life is definitely shorter, and the re-
the function of making high starting currents, long life and sponse time is long and prevents the use of higher operation
reliable operation. frequency. The capability of switching surge currents is also
3. High resistance to shock, vibrations and environmental considerably smaller.
pollution.
4. No electromagnetic interference owing to completely elec- SSR’s provide the possibility of switching at ”zero” for resistive
tronic control. load and, then the voltage on the load increases gradually,
5. High operation speed and high operation frequency. which, in some cases, e.g. an electric bulb, affects significantly
6. Low power necessary to control the relay. the period of life. This limits surge currents too.
Disadvantages: For inductive loads, relays which switch at maximum voltage
1. High resistance in switching on state, which causes gene- are useful - conduction occurs at supply voltage peak value,
ration of heat and necessity to use radiators. then the surge current is minimized.
2. Considerable voltage drop on the interface (1 - 1,6 V).
3. Sensitivity to overvoltage, necessity to use a varistor or RC
circuit.

Among the basic types of electromechanical relays, monostable and bistable relays should be considered separately.

Mono- and bistable relays

Monostable relays Bistable relays
A monostable relay is an electrical relay which changes its A bistable relay changes its status as affected by the appro­
status due to a supply value of the appropriate parameters priate supply value of the appropriate parameters and remains
and returns to the previous status when the parameter ceases in the changed state even after the value has ceased. Another
or changes. application of the appropriate supply value is necessary for the
relay to change its status again and return to the previous state.
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 Relays
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Further classification of relays may be based upon the functions they perform, e.g. all-or-nothing relays, step relays,
latching relays, polarized relays, reed relays.

All-or-nothing and step relays

All-or-nothing relays They may be energized by supply or disconnection of voltage
The term identifies the relays designed for operation at the (or current) within a given range.
value that is: Step relays
- higher than the make value, or The relays have two or more rotational positions, and they
- lower than the return value. move from one step to another in consecutive operations with
This type of relays must be supplied by a particular range of the use of energizing pulse. They usually move the contacts
voltage (or current). with the use of cams.

Latching relays
The latching relay is a non-polarized bistable relay. It changes The circuit applied
its state at the supply value and remains in the position after There are two different types of the latching relays:
the value has ceased. In order to change the state of the relay
again, another actuation is necessary. The crucial part of the - single winding latching relays with the external release
latching relay is the core made of special magnetic iron which resistance to limit the current intensity (Fig. 5).
remains magnetized ever after a voltage pulse has been ap-
plied. The core consists of a nickel base with aluminum, titanium
or niobium added (55-85% Co, 10-12% Ni).
Fig. 5. Circuits with single winding latching relays
Function
Energizing condition: OFF state
As the wiring is supplied with a voltage pulse of direct current
V1 (selected from the recommended supply voltage range) for
the duration of ti, the electromagnetic field grows immediately, A1 (1)
the core becomes magnetized and the relay is energized (the
normally open contact closes). When the pulse declines, the
relay remains in the ON state owing to the permanently ma- Rd A2 (2)
gnetized core (Fig. 4). U

Fig. 4. Latching relay, electrical circuit A1 (1)

Rd
NC NO A2 (2)
U
Vl =

Thus, the magnetic polarization of the relay depends on the

polarity of the supply voltage. The relay switches to the OFF
state on supply of the voltage of the opposite polarity which
changes the magnetic polarization of the core. The sole
change of the supply polarity will not cause the release of the
relay. This requires a change of the polarity, and the value of
the energy supply must be within the range of the actuation
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(energizing) values.

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 Relays
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- latching relays with two windings and two different voltage Fig. 6. Circuits with two winding latching relay
ranges for ON / OFF operation (Fig. 6).

It is important to bear in mind that for the appropriate operation

the relays require a minimum pulse of 10 ms. In order to avoid
overheating, the maximum time of supply is usually limited,
too. The aforementioned relays may also be supplied with
alternating voltage owing to the external diode which rectifies A1 (1)
U
the alternating current to the pulses of minimum duration of A2 (2)
A3 (3)
10 ms (half of the period). The applications of latching relays
are the same as the applications of the normal version relays.

U A1 (1)
A2 (2)
A3 (3)

Polarized relays
Polarized relay is a relay with permanent magnet which pro- The magnetic streams overlap. The supply value must be of
vides addi­tional magnetic force that reduces the energy con- the appropriate polarity, i.e. the same as the polarity of the
sumption. The magnetic field required for pulling the armature magnet. There are mono- and bistable versions of these relays.
is partly generated by the coil and partly by the magnet.

Reed relays
The remarkable advantage of the reed relays is that they are Fig. 7. Hermetic contact
hermetically sealed and, thus, resistant to atmospheric corro-
sion. They are very fast (10 to 20 times faster than electrome-
chanical relays) and at the range of the rated contact load they Gas tube
offer highly reliable switching operations, and extremely long
life. The fundamental part of a reed relay is a hermetic glass
tube, commonly called the magnetic (reed) contact.
The magnetic (reed) contact consists of two flat, ferromagnetic
lap contacts of the reed relay separated by a small air-clearan-
ce, hermetically closed in a glass tube. The contacts of the
reed relay are fixed to the ends of the glass tube and, thus,
they serve as supports. If the free ends of the reed contacts
are exposed to the magnetic field, the stream in the clearance
between the reed contacts will make them cooperate.
When the magnetic field ceases, the reed contacts will part from
each other as a result of the stress of the spring placed in the
contacts. This way, the contacts provide an operating magnetic
clearance, and they close and open the electrical circuit.
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 Relays
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Terminology

Actuation condition - in case of a monostable relay: specific Normally open contact - a contact which is closed when the
status of a relay while it is supplied with a given supply value relay is actuated, and open when the relay does not operate.
which has been energized; in case of a bistable relay: a status
opposite to rest condition indicated by the manufacturer. Normally closed contact - a contact which open when the
relay operates, and closed when the relay does not operate.
Actuation - change from rest condition to actuation condition.
Changeover contact - a set of two contact circuit made of
Return - in case of a monostable relay: change from actuation three members of which one is common for two contact circuits;
condition to rest condition. when one of the circuits is open, the other is closed.

Reset - in case of a bistable relay: change from actuation Contact gap - a gap between contacts at open contact circuit.
condition to rest condition.
Making capacity - the highest value of electric current which
Constant operation - operation during which a relay remains may be connected by a contact when specific conditions are
actuated for the time long enough to reach heat balance. met, e.g. making voltage, number of operations, power factor,
time constant.
Cycle operation - operation during which a relay performs
several make cycles, where intervals of actuation and absence Maximum continuous current - the maximum value of the
of actuation are defined; actuation time of the relay is such that current which may flow through a closed contact continuously
heat balance of the relay is impossible to be achieved. in specific conditions.

Coil thermal resistance - the ratio of increment of the coil Isolating air gap - the minimum distance in the air between
temperature and the input power, measured after the time two conductive parts or between a conductive part and exposed
sufficient for achieving heat balance. surface of the relay.

Make voltage - the coil voltage value at which the relay is Isolating surface gap - the minimum distance on the surface
actuated. of the isolating material between two conductive parts.

Return voltage - the coil voltage value at which a monostable PTI - indicator of resistance to creeping current - numerical
relay returns to the previous condition. value of proof voltage expressed in Volts, which may be resisted
to by the isolating material without formation of conductive
Reset voltage - the coil voltage value at which a bistable tracks, defined in specific conditions of experiments.
relay is reset.
CTI - a comparative indicator of resistance to creeping current
- numerical value equal to maximum voltage expressed in
Volts, which may be resisted to by the isolating material without
formation of conductive tracks, defined in specific conditions
of experiments. 22.02.2018

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 Relays
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Coil operating voltage range

The admissible operating voltage range for the coil as the The make voltage is the minimum operating voltage of the coil.
function of the ambient temperature is shown in the chart for The make voltage grows along with the increase of the winding
RM85 relay. temperature. Since the resistance of the copper wire changes
by 0,4% per Centigrade, the growth of the coil temperature
The maximum operating voltage of the coil is limited by the caused by a higher ambient temperature or by contact load
increase of the coil temperature caused by the heating of the results in the drop of the coil current and, thus, the increase
winding. The increase shall not exceed the admissible tempe- of the voltage required for the relay electromagnet to operate.
rature defined for insulation materials.

Fig. 8. Coil operating range - DC

A - relations between make voltage and ambient temperature at

no load on contacts. Coil temperature and ambient temperature
are equal before coil energizing. Make voltage is not higher
than the value read on Y axis (multiplication of rated voltage).
B - relations between make voltage and ambient temperature
after initial coil heating up with 1,1 Un, at continues load of In
on contacts. Make voltage is not higher than the value read
on Y axis (multiplication of rated voltage).
1, 2, 3 - values on Y axis represent allowed overvoltage on coil
at certain ambient temperature and contact load:
1 - no load
2 - 50% of rated load
3 - rated load

Coils - overvoltage protection

While using electromagnetic relays in electric circuits, it sho- Fig. 9. DC coil voltage during switching off
uld be borne in mind that coils are the source of significant
overvoltage which may disturb the operation of the equipment
in which electromagnetic relays are applied. Furthermore, due
to overvoltage the equipment in which electromagnetic relays Un
are used may not meet the requirements of electro­magnetic
compatibility. 0

Relay coils have high inductance during operation, which

causes a rapid increase of the coil voltage on switching off.
Such a situation occurs in both DC and AC voltage coils. If, for
Voltage [V DC]

example, the coil is switched off by a transistor, the latter may

be damaged. Moreover, such pulse disturbances my affect
negatively the nearby electronic systems.
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Time [msek.]

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 Relays
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Fig. 10. AC coil voltage during switching off Furthermore, when the varistor is supplied from the mains, the
varistor protects also the relay coil from being damaged by the
voltage pulses that occur in the mains. The varistor protection
may be also applied in DC coil relays. However, the overvoltage
values on switching off are much higher than in the case of
protection with the use of a suppressing diode.

0 Another way to limit the overvoltage values during coil switching

off is a parallel connection of an R-C two-terminal network to
the coil. The network limits the overvoltage well, it is inexpen­
sive, and it only slightly increases the relay release time.
Voltage [V DC]

No ceramic capacitors should be used whereas it is recom-

mended to use foil capacitors. On selection of a resistor, it
should be taken into consideration that quite a large amount of
power dissipates on it during the transition process and, thus,
the resistor’s power shall not be less than 0,5 W.

Relpol S.A. offers both relays with integrated overvoltage

Time [msek.]
protection elements (diodes or varistors) and ready-to-use
overvoltage protection modules to be mounted in plug-in
For coils supplied with DC voltage, the best and simplest sockets.
solution of the problem is a parallel connection of a standard
rectifying diode to the coil terminals. During the current flow, the R2N, R3N and R4N relays with DC coils are also in the version
diode has a reversed bias due to the voltage drop on the coil. with suppressing diode mounted inside the relay. However,
On switching off the coil voltage, the diode starts conducting varistors are not mounted inside these relays. Ready-to-use
which results in the coil voltage increase merely by the voltage overvoltage protection modules of M series may be used with
drop on the conducting diode. Designers of electronic systems the relays and then the modules are mounted in GZT., GZM.
with electromagnetic relays practically always use suppressing and GZMB. series plug-in sockets. Modules with a diode (DC
diodes connected in parallel to the relay coil. The 1N4007 diode coils) or with a varistor (DC or AC/DC coils) are available.
is a perfect solution in most of such cases. Diodes remove
overvoltage extremely efficiently, they are a cost-effective and R15 relays are manufactured solely with the overvoltage pro-
reliable way of suppressing coil self-induction voltage, which tection element integrated, i.e. with the suppressing diodes
does not involve complicated calculations The only weak point for DC coils (two-, three-, and four-pole versions) and with
of the diode system is a remarkable (threefold) increase of varistors for AC coils (two-, and three-pole versions). In the
the relay release time. The release time may be reduced by case of a suppressing diode as the overvoltage protection
connecting an additional resistor in serial to the diode in which element, the coil supply polarity must be as follows: A1 terminal
case, however, the over­voltage value grows while the coil is ”+”, A2 terminal ”-”. note: the specified polarity does not refer
being switched off. to the relays R15 4 CO – four-pole for which the coil supply
polarity must be as follows: A1 terminal ”-”, A2 terminal ”+”.
The diode protection cannot obviously be used with AC coil
relays. In such cases, two types of protection are commonly Ordering codes of the overvoltage protection elements integra-
used, i.e.: ted in the relays (as add-on equipment) are as follows:
- varistor protection, and D - suppressing diode;
- R-C two-terminal network protection. V - varistor.

Metal-oxide varistors have similar current-voltage characte­ While using an overvoltage protection element, the user may
ristics to that of a bidirectional Zener diode. When the voltage be assured that the overvoltage that occurs on switching the
between the varistor terminals exceeds a given limit value, coil off will not affect negatively the coil control circuits or any
it starts conducting, and, thus, it shunts the inductive load other electric and electronic circuits.
(the relay coil) with its differential resistance. The maximum
overvoltage value on switching off depends on the limit voltage
of the varistor.
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 Relays
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Switching section: main diagrams and mechanical solutions

There are various contact configuration diagrams related with Contact Marking
different application requirements, i.e. normally open contacts type Relpol S.A. Zettler USA
(NO), normally closed contacts (NC) and changeover contacts.
These are the basic configurations used for designing all the CO 1 C SPDT
contact diagrams of relays. With the use of the basic contacts, NO 2 A SPST-NO
many relay circuits may be built in order to apply relays suc- NC 3 B SPST-NC
cessfully. The only theoretical limitations are the dimensions
of relays, electromagnetic energy, switching energy and the SP = single pole
complexity of drawings. The contact configurations available ST = single contact (normally open or normally closed)
in a relay are determined by the number of poles, type of the NO = normally open contact
contacts (changeover or normally open/closed), and normal NC = normally closed contact
position of the contacts (normally open or normally closed). DP = two contacts
In table next are listed symbols depicting exact type of DT = changeover contact
contacts.

Other manufacturers of relays apply also different ways of

defining the configuration of contacts. They may be found
in catalogs and catalog cards published by the companies.

Terminals marking

Terminals marking under Polish Standard EN 50005. Coil terminals are always literal-
-numerical.
Contacts terminals are always marked numerically with two
digits, where: The scheme of marking of ter-
- the unit digit is the number of functions, minals of contacts and coil for a
- the decimal digit is the number of sequences. four-track relay (see below). A1 A2

Single-track relay Double-track relay

12 14 22 24 32 34 42 44 A2

14
11 14 24

11 21
12
12 22 11 21 31 41 A1
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 Relays
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Contacts and shapes of contacts

Contact pressure
When two contacts come together to close the electrical circuit, Fig. 11. Effect of the contact force
they touch each other within the area that depends on the shape
of the contacts. The force (N) with which the contacts push
against each other as measured on the contact axis, divided Weak contact
by the area of the contact (mm2) equals the contact pressure
(N/mm2). It is practically impossible to determine the real con-
tact area as it depends also on the roughness of the contact Few contact points
surface. The contact pressure is determined by the contact
force. In order to obtain a large contact area, the contact force
must be increased so that the contact area roughness may be
deformed. A low force means a few effective contact points
and a small area of the contact (i.e. a high contact resistance). Stronger contact force
On the other hand, a stronger force increases the number
of contact points and the total contact area (lower contact
resistance). The contact force may be increased only to the limit More contact points
defined by the mechanical strength of the parts and as much
as it is allowed by the supply voltage sensitivity.

Manufacturers of relays use different shapes of contacts

according to the relay designs and applications.

Fig. 12. Shapes of contact rivets

Bi-metal rivet Tri-metal rivet Solid rivet

Contact material
Copper Contact material Copper Contact material
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 Relays
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Cylindrical contact rivets

Cylindrical contact rivets are usually used in their bimetallic, Fig. 13. Contact movement
solid or other versions, similarly to the contact parts of miniature
relays owing to their optimal switching capabilities and easy
assembly. Normally, the contacts are connected between the
flat surface of the fixed contact and the spherical surface of the
movable contact (the common contact). Principally, the com-
mon contact is a solid one whereas the fixed contacts (NC and
NO, when in switching operation) are bimetallic ones (Fig. 12).
The head of the central solid contact is ready to use on one
side, and it is shaped during assembly on the other side.
The flat-spherical connection between the contact surfaces
is necessary for the reduction of the area of connection with
the simultaneous increase of the contact pressure. Moreover, Initial state Final state
relative surface movement (roll) occurs then, which is useful
in terms of enhanced contact performance (Fig. 13).

Small-profile contact
Fig. 14. Small-profile contact
A pressed strip of metal or contact alloy is automatically wel-
ded to the spring material prior to the cutting process. During
the cutting process, the spring strip is cut together with the
contacts, and the contact is formed to the required shape (Fig.
14). This solution is useful as it provides avoiding a dangerous Contact material
voltage drop on the spring-contact connection. This allows the
appropriate selection of the contact shape.
Contact spring
material

Shaped
contact

Cross contacts
Fig. 15. Cross contact
While using small-profile contacts it is possible to design a con-
tact coupling with cylindrical surfaces and perpendicular axes.
This way, a limited contact area and high contact pressure may
be obtained. Moreover, during switching, two contacts operate
like ”two knives”, thus maintaining a very clean contact surface.

Contact point

Fixed contact axis

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Movable contact axis

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 Relays
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Twin contacts
For some applications (e.g. low-level signals - safety systems), Fig. 16. Twin contact
in order to enhance the contact reliability, twin contacts are
used. Small-profile rivets or contacts are placed one next
to another on the same forked spring (springs of fixed and
movable contacts). Thus, duplication of the contact points may
reduce the probability of error occurrence by half.

Contact materials

In the issues related with switching, contact materials and special alloys play an important role, and each application
requires the appropriate assessment of the electric load, ambient conditions and other information in order to make
the proper choice.

Surface finishing
Precious contact materials are widely used due to their high to the contact resistance. The aforementioned materials may
conductivity. However, it is silver and its alloys that are exposed be plated with gold or another noble metal (metals that are
to the effects of the surface corrosion caused by sulfur conta­ more resistant to corrosion and/or oxidation, i.e. platinum,
mi­­na­tions in the atmosphere (SO2 - sulfur dioxide). Layers of palladium, etc.).
sulfur deposit on the contact surfaces, which is highly harmful

Cleaning
Cleanliness is very important for the process of relay assembly That is why contacts, working parts and (in some applications)
due to the necessity to keep the internal parts of relays free of the whole relay without a dust cover are cleaned immediately
dust and other particles which may affect the area between the prior to their enclosing.
contacts and disturb the proper course of switching operations.

Plastic contaminants
Due to temperature, internal parts of the relay made of plastic The treatment consists in high-temperature degassing process
may produce gases and vapors. If they are not removed from in which, at low atmospheric pressure, plastics emit gases and
the relay, they may deposit on the contact surface, which will vapors. The process ends with stabilization of the ambient
increase the contact resistance. This is often the case in tight pressure which allows avoiding reactions inside the relay that
relays where it may appear extremely dangerous if the plastic might occur in the presence of humidity and oxygen.
has not been previously treated in a special manner.
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 Relays
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Contact resistance and influencing factors

The main function of electric contacts is to close an electric Fig. 17. Basic circuit
circuit to provide flow of current (I) at voltage (U). This ”simple”
operation requires certain special characteristics of contacts,
which depend on materials, shapes, mechanical parameters,
etc. When current (I) flows through an electric circuit, the circuit
resistance (R) reacts against the current flow according to the
following rule: U = R x I

G L
The value of R consists of two different resistances: circuit
resistance Rc and contact resistance Rr.
Thus:
R = Rc + Rr and U = I x (Rc + Rr)
The dissipated power Pw in the entire circuit equals:

G = Generator L = Load
Pw = Pc + Pr = (Rc + Rr) x I2

The value of the circuit resistance Rc usually spreads evenly Question:

along the length of the circuit (cables, wires, printed circuits, Find the value of the voltage drop caused by the relay contact
etc.), and Pc dissipates in the same manner (low increase of resistance in the next circuit under the following circumstances:
temperature); on the other hand, however, Rr is entirely concen- - electric load: I = 1 mA, U = 5 mV,
trated inside the relay (problems related with the temperature - relay contact resistance (mΩ):
rise). This proves the extremely important role of maintaining d) 10 mΩ
the relay contact resistance on as low a level as possible. This e) 100 mΩ
is important in applications of both high and low power. In the f) 400 mΩ
first instance, there is the problem of temperature rise inside Solution:
the relay whereas in the second case high contact resistance The voltage drop on the contact equals:
may disturb the proper operation of the device. d) Rc x I = 0,01 x 0,001 = 0,01 mV
e) Rc x I = 0,10 x 0,001 = 0,10 mV
Question: f) Rc x I =0,40 x 0,001 = 0,40 mV
Find the values of power (W) dissipation in the relay contact
circuit under the following circumstances: High values of resistance cause a significant percentage of
- electric load: I = 5 A, U = 250 V AC, voltage drop which may be dangerous in some devices. This
- relay contact resistance (mΩ): is important because high contact resistance usually means
a) 10 mΩ instability of the contact resistance. In applications of low-level
b) 50 mΩ signals (measurements, etc.) the capability of reaction to the
c) 300 mΩ contact resistance is a fundamental requirement. The following
Solution: factors affect the contact resistance:
a) Rc x I2 = 10 mΩ x (5 A)2 = 0,25 W - contact pressure,
b) Rc x I2 = 50 mΩ x (5 A)2 = 1,25 W - materials,
c) Rc x I2 = 300 mΩ x (5 A)2 = 7,50 W - surface finishing,
- cleaning,
Based on the above, it may be stated that the power dissipa- - internal contaminations of the plastic relay parts.
tion inside the relay reaches undesirable levels at high contact Each individual influence must be taken into account.
resistance.
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Alloys and contact materials

The choice of the contact material depends on the application. The following are the most commonly used materials:

Silver Ag Tungsten
Pure silver (99% Ag) is of the highest electrical and thermal This is the hardest material, highly resistant to sticking. It has,
conductivity as compared to any other known metal, and it however, a relatively high contact resistance. Because of the-
proves good resistance to oxidation but it is affected by the se characteristics it is usually used in electric circuits where
presence of sulfur in the atmosphere. The sulfur forms silver short current peaks appear, and where the material prevents
sulfide which increases the contact resistance. In order to avoid the contacts from welding to each other: leading loads, motor
the problem, the contact surface is plated with gold (5 µm) as loads, lamp loads (especially fluorescent lamps), etc. The range
the latter remains free of silver sulfide (no chemical reaction). of applications starts from 60 V and 1 A.
This is a good version of the contact widely used for switching
low-level loads from µV to 24 V DC and AC, and from µA to Silver + tin oxide (tin dioxide) - AgSnO2
0,2 A, and in any case with no electric arc as it might damage The AgSnO2 material is of similar properties to those of AgCdO.
the layer of gold and expose silver to the harmful presence However, the former has a higher thermal stability and better
of sulfur. resistance to transfer of material from one contact to the other,
which provides longer life in DC applications. The AgSnO2
Silver - cadmium oxide AgCdO contacts wear evenly and they are recommended for applica-
This compound (90% Ag - 10% CdO) has a wide range off ap- tions at the loads that create inrush current and at inductive
plications in power loads owing to its good resistance to welding loads.
and the effect of electric arc suppression. The compound may The contact ratings depend to a great extent on the level of
be used from 12 to 380 V AC and from 100 mA to 30 A. It is the oxide in the compound, the manufacture method and the
used particularly for resistive and inductive applications such as presence of admixtures which are used by contact materials
motor loads, heating resistors, lamp loads, solenoids, etc. The manufacturers mainly to reduce the contact resistance and to
material is a standard one to meet most of the requirements enhance the resistance to material transfer.
of the customers. The problems related to sulfur do affect it The AgSnO2 material offered by Relpol S.A. in miniature relays
but the presence of electric arc and relatively high voltage and contains a low admixture of indium oxide (In2O3) which is a
intensity of current make the problem imperceptible (the electric universal material. Apart from good results achieved at lamp
arc and voltage pierce the sulfide layers). loads, the material performs perfectly at resistive loads and
switching currents up to 16 A.
Silver - nickel AgNi
The alloy (90% Ag - 10% Ni) is the most suitable one for swi- Gilding - Au
tching DC loads and avoiding material transfer that appears Contact gilding with 0,2-0,5 µm gold layer is usually applied in
at DC and at medium voltage and intensity of current (1-10 A; order to protect the basic material from oxidation during product
6-60 V DC). This is a physical phenomenon of moving the ma- storage. The protective gilding is not resistant to mechanical
terial from one contact to the other (from cathode (-) to anode wear and it is quickly destroyed in course of the relay switching.
(+)). This results in quick wear of contacts and dangerous Contact gilding with 3-5 µm layer of gold is used as protection
reduction of the contact clearance. from corrosion and to enhance signal circuits switching. Thick
gilding provides the lack of microscopic pores, perfect resistan-
ce to corrosion and to formation of non-conductive layers.
Fig. 18. Transfer of contact material However, gold is very soft, easily becomes mechanically worn,
and its low melting point may limit the electric life of the contacts
which switch high currents.
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Electric life of relays

The electric life or switching capacity is expressed as the the contact resistance (or contact voltage drops) which stops
minimum number of cycles which the relay may perform at a the switching operations after it has reached a higher value
given load and under certain circumstances. The ”cycle” means (the limits depend on the application). The specifications of
a full switching operation from OFF state to ON state and to relays indicate the electric life as the number of cycles at rated
OFF state again. The electric life ends when the contacts are current and voltage, and at constant frequency and ambient
no longer capable of switching electric load within the range of temperature.

Fig. 19. Chart of electric life of a relay

For example, the electric life of the RM85 relay is:

Number of cycles: 7 x 104 at 16 A and 250 V AC - 50 Hz, resistive
load, 600 cycles/hour - ambient temperature 85 °C.
In practice, customers require electric life also at lower values
of current intensity. Thus, on the basis of tests, the curve of
electric life is defined and the curve shows the dependence of
electric life (number of cycles) on switching capacity (Fig. 19).

Inductive loads cause high contact wear which reduces the

Fig. 20. Ratio of correction coefficient
relay life. The reduction has been defined on the basis of tests,
to power coefficient
and it is expressed as the correction factor for resistive electric
life (depending on the load power factor) which should be used
to define the projected life.

Question:
What is electric life of the RM85 type relay for the following
electric load: 8 A / cosφ = 0,4 / 250 V AC; 600 cycles/hour. The
chart in Figure 19 shows that the projected life is approximately
150 000 cycles at resistive load (cosine = 1).
The chart presented in Fig. 20 proves that at the cosine power
factor which equals 0,4 the correction factor is 0,7. Thus, the
projected electric life under the aforementioned conditions is
150 000 x 0,7 = 105 000 cycles.

Reliability
Charts of electric life of a relay in the function of load power in a device means the necessity of replacement. Given the
are useful in estimating the reliability parameters. The value frequency of operations of a relay in a device and the number
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found in such charts may be used for defining the statistical of cycles defining its life, the mean time to failure (MTTF) may
parameter of B10 life, i.e. the number of cycles following which be estimated, which may then be used for calculation of MTBF
10% of the relays population will fail. Electromagnetic relays for the device.
are unreparable elements and, thus, any damage to them

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Switching at alternating and direct current

Various problems occur at switching AC and DC loads of high Fig. 21. Switching states (I, II)
power, and various aspects shall be taken into account in order at the frequency of 50 Hz of alternating current
to understand the nature of the phenomenon. In AC current
circuits (of the frequency approx. 50 - 60 Hz), the relay contacts
may open in two possible states of the operating voltage due to Voltage 50 Hz
the course of the voltage and the phenomenon of the electric
arc (see Fig. 21). IV

Switching at point I: III

Voltage value is close to zero. I
No electric arc occurs. Time

II

Switching between points I and II: these reasons, in miniature relays there are physical limits
There may be two situations in which the voltage grows or related to the above parameters, which reduce the maximum
drops. In both cases, arc discharge occurs but it is suppressed AC switching voltage to approximately 380 V. The inductive
due to the transfer of the voltage via the zero value. The electric loads of AC are worse as compared to the resistive loads due
arc discharge depends on the voltage value, contact clearance, to contacts wear since the load inductance grows and, thus,
current intensity, shape of contacts and on materials. Due to a constant arc appears together with its harmful effects.

Arc breaking

In DC devices, the arc breaking is a crucial problem because Fig. 22. Maximum switching capacity at direct current
the voltage does not transfer via the zero value as it does at
alternating current. Thus, when the electric arc appears, only
the contact clearance and the properties of the contact ma-
terials contribute to the arc suppression. Relays usually have
a physical limit that depends on the above parameters which
make the relays incapable of switching the load at current
intensity and voltage higher than the specified values. The
values are expressed in the form of a curve which defines the
maximum switching energy (U x I) at the constant time value
L/R of resistive and inductive loads while L (inductance) is
expressed in henries and R (resistance) in ohms.
L/R is principally expressed as a value that equals 40 ms (mil-
liseconds) for inductive loads, i.e. a mean value for devices.

Example (Fig. 22):

The maximum admissible switching intensity of direct current
for the R3N relay at 230 V DC at resistive and impedance
loads are 210 mA and 120 mA respectively. The values assure
the arc suppression. Suppressing circuits are also useful for
alternating current devices.
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Suppressing circuits

In order to protect contacts against their damage by electric must be emphasized that diodes prolong the time of switching
arc, protection circuits are used which are fitted in parallel to off the relay considerably, which delays opening of the contacts
contacts of the relay or to the load. Appropriate suppressing and this is conducive to their burnout.
elements may also be connected both to the contacts and
the load. In order to decrease the effect of the arc suppressing circuit, on
switching off the load, two Zener diodes may be used instead
The most common method of arc suppression in DC circuits of the diode parallel to the load. In such a circuit, the inverse
is using a diode in parallel to the load. This is an efficient and voltage is limited by Zener diode do the regulated voltage. The
cost-saving solution applicable at various values of the load. breakdown voltage of the Zener diode must be higher than the
The inverse voltage of the diode should be at least 10 times supply voltage of the circuit. The disadvantage of this solution
higher than the rated voltage of the circuit, and the conduction is its lower effectiveness and higher cost.
current should be equal to or higher than the load current. It

Fig. 23. Protection circuits

Diode Zener diodes RCD circuit

RL RL Z1 RL
DC D AC/DC D DC D
Z2 RV
L L L

Varistor RC circuit RC circuit

RL RL RL RV
AC/DC AC/DC RV AC/DC
L L L C

A varistor is another protection element of current-voltage This helps to maintain low voltage on the relay contacts and,
ccharacteristics similar to Zener diode. For low voltages it thus, diminish the effect of the electric arc. Ehen the contact
shows high resistance and, then, it is practically disconnected closes, the capacitor connected in parallel to the capacitor
from the circuit whereas when the voltage exceeds certain consists limitation of current. Thus, the RC circuit optimizes all
voltage, characteristic for the given varistor, its resistance the intermittent processes in the course of opening and closing
decreases quickly and, then, it shunts the inductive load with of the contacts. At AC voltages the load impedance must be
its internal resistance. lower than the RC circuit impedance.

Unlike diode and varistor circuits, RC circuits may be connec- In order to enhance the effectiveness of arc suppression in
ted in parallel both to the load and to the contacts of the relay. direct current circuits of high inductiveness of the load, RCD
When the contact opens, the capacitor connected in parallel circuits may be used, where the RC element is connected in
starts charging itself and its voltage grows at the time constant parallel to the relay contact and the diode - in parallel to the
of R and C values. load.
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Fig. 24. Nomogram for defining optimal values of R and C

Special loads

Bulb load
Closing of the contact with bulb loads (a lamp with tungsten The following must be taken into account for bulb load swit-
fiber) causes problems due to high current peaks related with ching:
the low resistance of the fiber when it is cold. For example, - maximum load of the bulb,
a 60 W - 220 V AC bulb has the ”cold” resistance of approxi- - contact material.
mately 60 Ω which corresponds with a current intensity of For example, for the RM96 relay with AgCdO contacts the
3,66 A (for a few milliseconds). On the other hand, the current maximum admissible bulb load is some 1,000 W which corre-
intensity of a hot bulb is 0,273 A (the ratio is then 1:15). This sponds with the current intensity of 4,5 A and the alternating
illustrates the high load that occurs on the contacts during the current voltage of 220 V. In other relays of higher loads the
bulb switching (a hazard of contact welding or sticking). contacts are made of AgSnO2.

Motor loads
The motor loads are inductive loads which operate in a parti- material is related with the aforementioned load characteristics,
cular manner while switching on. A current peak occurs as a especially when the capacitor is connected to the motor. In
result of the motor inertia which is related to the mechanical such particular cases, the contacts are made of tungsten and
load used in the motor, and which in the starting phase is 5-10 AgSnO2. The motor load is usually expressed in HP (horse­
times higher than the current in the steady state. Furthermore, power) where 1 HP equals approximately 745 W.
when the motor is being switched off, harmful action related with Example: R15 relay - the rated motor power of the contact is
impedance loads occurs. Thus, the correct choice of contact 1/2 HP.

Capacitance loads
This is the worst contact load as for switching on due to a The problem of contact welding may be avoided in two ways:
sudden increase of the current intensity peak which occurs - via using the AgSnO2 contacts,
when the capacitor is discharged (a phenomenon similar to a - via reduction of the current intensity peak by introduction of
22.02.2018

short circuit). The current intensity at the peak to be switched a resistor to limit the current.
on may reach the values of hundreds of Amperes in a very The same problem occurs at contacts closing with a charged
short time (microseconds). capacitor, i.e. a rapid discharge occurs.

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Switching time and contact bounce

On the relay coil supply during opening and/or closing, the impulse and the preset closing and/or opening of the contacts
operation lasts in time depending on the electric and mecha- is the sum of the effect of the electromagnetic system and the
nical inertia of the parts. The delay between the coil supply switching section.

Electromagnetic system
The current flows through the coil with the delay caused by the more, the movable parts such as the armature and the pusher
coil inductance which resists to the current stream. Further- react to the movement due to the action of the magnetic stream.

Switching section
The elastic forces stored in the contacts and springs, and their phase. During the release phase the operating time is shorter
elastic strain, react to the movement of the relay parts. The due to the absence of the magnetic circuit delay. It is really
phenomenon is also affected by the inertia of the contacts so that on removing the supply voltage from the terminal, the
mass. The delay times of the miniature relays usually reach current that flows through the coil wire stops suddenly and the
the value of a few milliseconds (5-15 ms) during the switching relay is released with the elastic energy stored in the contacts.

Fig. 25. Switching time Fig. 26. Release time

Coil supply
Coil supply current
current Operating time Bouncing time
Normally open
contact
Normally open
Normally closed contact contactny Release time Bouncing time

1 ms
1 ms Normally closed contact

Bounces Bounces

The operating time of an inactive relay is the time interval from The release time of the active relay is the time interval from the
the moment of the supply of the voltage to the relay coil to the absence of the supply voltage to the first opening (or closing)
time of the first closing (or opening) of the contact. of the contact.
If the relay has more than one contact, the time of closing (or If the relay has more than one contact, the time of opening (or
opening) of the last of the contacts is taken into account. closing) of the last of the contacts is taken into account.
The operating time includes the time of opening the normally The release time includes the time of opening of the normally
closed contact and the time of closing the normally open open contact and the time of closing the normally closed
contact. contact.
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Bouncing
In the phases of switching and release, when the contacts The ”contact bouncing” cause constant closing and opening of
close, they never perform the operation at the same time but the contacts. This particularly affects the contact ratings such
the clash between two contacts makes the contacts bounce. as electric life and signal switching.

Sinusoidal vibrations

The electromechanical relay is strongly affected by dynamic is on or off. The contact continuity is monitored with an oscil-
phenomena which may change its projected characteristics loscope at a low-level load on the contacts. The test allows
constantly or temporarily. The devices in which vibrations defining of the frequency range [Hz] and maximum value of
occur must be thoroughly tested so that we might find out the acceleration, at which the relay may operate with no loss
the quality and essence of the stress. Machine tools, auto- of contact continuity (interval of 10 µs) or without any durable
motive devices, assembly machines, and principally every damage. The standard values (which meet the requirements
instrument in which the electronics of the drive is affected of a wide line of devices) for miniature relays reach 10 G at
by the presence of movable parts (motors, vibrators, valves, the frequency range from 25 to 100 Hz. The values refer to
etc.), may be exposed to the consequences of the problem. the worst case which usually occurs in the most critical test
Relpol S.A. usually tests the relays via exposing them to conditions (the relay with no supply in a given axis of vibrations).
sinu­soidal vibrations at the constant acceleration (G) within a For tests at a low frequency range (a few hertz), instead of
particular range of frequency. Moreover, the relays are tested the constant acceleration, a constant movement is simulated
along the main axes (x, y, z) and in two basic directions for which corresponds with a given value of acce­le­ration (e.g. from
each axis. As a rule, the relays are tested with the printed circuit 10 to 25 Hz for the amplitude of 2,5 mm). The tested frequency
board mounted (sockets, materials, etc.). at which the constant movement changes into the constant
The tests are made in two stages, i.e. resonant test and fatigue acceleration is called the ”transition fre­quency”, e.g. at 55 Hz
test. The relays are tested at the states where the coil voltage 10 G it corresponds with 1,5 mm.

Current surges

The maximum value for miniature relays is 10 G for maximum of the three main axes (x, y, z), in two basic directions for each
peak acceleration and 11 ms of the impulse duration. As for the axis. Three surges shall be applied to each state. The tested
sinusoidal vibrations, the sample shall be subject to an ohm test relay shall not open the contacts (10 µs interval), and it must
for surge both at the ON and OFF states within the arrangement operate perfectly at the end of the test.

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Hermetic relays - soldering and cleaning

The necessity to use tightly closed and hermetic parts in de- of the stream in the process of soldering and cleaning, and
vices arises from two different reasons, i.e. protection of the protection of the internal parts from atmospheric contamination.
internal parts (contacts, mechanisms, wires) from penetration

Relay handling during PCB assembly, soldering, cleaning and PCB coating
Handle the relays carefully. Any hitting the relay or dropping The PCB cleaning process: is only allowed for relays with
of the relay, even from a small height onto a hard surface ge- RTIII protection class with a closed vent hole. Avoid cleaning
nerate very strong mechanical shock, can cause permanent in a cold liquid immediately after the soldering process be-
damage, change of mechanical parameters and improper cause thermal shock causes the relay to become unsealed
operation. If the relay has fallen, we recommend you reject it as a result of the pressure difference and the cleaning liquid
and apply a new one. and/or flux can get into the relay inside. The penetration of the
flux into the relay inside may result in sticking of the armature
Mounting the relay: bending the relay pins is forbidden be- or contamination of the contacts, which leads to incorrect work
cause it can damage the relay. of the product. Additional care should also be taken to avoid
penetration of the liquid inside the relay - too high washing
Manual soldering: soldering iron power max. 60 W, max. iron pressure can damage the sealing of the relay. Recommended
tip temperature 360 °C, soldering time max. 3 s. Exceeding cleaning solvent temperature max. +40 °C.
the given process parameters may damage the relay.
It is forbidden to wash in ultrasonic washers, it may cause da-
Flux application: it is recommended to use modern fluxes mage to the coil or welding contacts as a result of ultrasound.
(no-clean type) to eliminate the need to wash the PCB after
assembly. Be careful careful when applying flux. Make sure It is recommended to use alcohol-based or aqueous cleaning
that the flux is applied in the minimum necessary amount, only solvents for PCB cleaning. When using other cleaning solvents,
from the bottom of the PCB on the pin side and does not flow the user should ensure that they do not have a negative im-
onto the top of PCB. Failure to follow this precaution may result pact on the materials from which the relay is built. Unsuitable
in damage the relay. cleaning solvents include: acetone, ethyl acetate, solutions
based on solvents or chlorine.
Wave soldering: applies to relays with protection class RTII
and RTIII. The level of solder wave should be set so that it does Application of conformal coatings: applies only to relays
not overflow onto the surface of the PCB. The solder tempera- with RTIII protection level. Conformal coatings for unsealed
ture must not exceed 270 °C and the soldering time must not relays (including relays with RTII protection level) should not
exceed 5 seconds. During pre-heating, the temperature on the be used. The materials for conformal coatings should be care-
component side should not exceed 100 °C. After automatic sol- fully selected - some materials are chemically active and have
dering, the PCB with the relays should be cooled down before a desctructive impact on the relays, eg. they can penetrate
the washing operation. The cooling speed should not exceed inside the relay or damage the relay seal, cause the relay to
5 °C/s to not damage the relay sealing due to thermal shock. malfunction. Avoid silicone-based coatings.
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Environmental contamination

The environment of the relay may adversely affect its opera- Fig. 27. Opening of the relay
tion. Humidity, industrial air, dust and particles that penetrate
the inside of the relay may affect the contacts, internal parts
and isolation. The environmental conditions in which the re-
lay and the device will be used shall be analyzed in order to
avoid such problems as resistance growth and corrosion of
the metallic parts.
If the ambient conditions are not arduous and/or the electric
load of the contacts is not critical (cleaning presence of the
arc), it is better to open the relay following the soldering and
cleaning processes to allow the useful exchange of the air with
the external atmosphere.
What is important for the thermal exchange (high switching
power) is the gas emission caused by the electric arc and the
residual contaminations with plastics. As explained before, the
process of sealing the relay includes degassing of plastics,
filling the relay with inert gas (nitrogen), and the process of
label closing or other methods.

Lead-free soldering

Eliminating of the lead used in the solders required both chan- Sn97Cu3 and Sn99Cu1 are good materials for soldering inter-
ging of the material and the production process which had to nal elements and for covering the terminals. They are modern
be adapted to different properties of the lead-free materials. alloys widely applied in electronics owing to their good physical
The differences between the physical properties of lead alloys properties. They are also a good and popular alternative for
and their lead-free equivalents available on the market are Sn60Pb40 and Sn63Pb37.
significant and, thus, the applicable features of soldering alloys In order to provide good tin-plating and soldering of the termi-
shall be thoroughly considered, and the flux must be precisely nals, it is important to select appropriate flux. Higher melting
selected in order to provide optimal conditions for the process. point of lead-free alloys results in higher oxidation and lower
Generally, lead-free alloys have slightly higher melting point, moistening and, thus, appropriate flux must be selected and its
higher surface tension and lower moistening than SnPb. This quantity shall be adapted to the temperature profile of the pro-
may cause production problem, i.e. damages to components cess. Too much heat delivered may cause evaporation of flux
due to thermal impacts, deforming of the PCB’s, flux splashes, before it moistens the solder, and use of stronger, aggressive
extending of the operation time to good joining, deforming of fluxes in higher quantities may require introduction of the ope-
plastics, etc. ration of washing away the residues of the soldering process.
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Types of relay terminals

Surface mounted Fig. 28. In course of mounting of the relay in the socket,
terminals (SMT) the clip functions also as a relay protective latch.

THT mounted terminals

Relay

Terminals to solder wires

and for sockets Retrainer /
retractor clip

Terminals for flat slide-in

(faston) connections

Plug-in
In miniature relays of high power to be mounted on printed socket
boards universal terminals are made so to provide fitting the
relays also in sockets mounted on 35 mm rail mount. Then,
relay terminals are connected to wires with screw terminals
of the socket. This allows mounting miniature relays on a 35 mm rail mount acc. to EN 60715
mounting board and enhances technical service of the device.
Sockets are fitted with retrainer / retractor clips which facilitate
dismounting of the relay and, when it is mounted in the socket,
the lever serves as a reliable latch which secures the relay on Current flowing Wire and stranded
via terminal [A] conductors
the mounting board.
above including up to cross-section [mm2]
– 3 0,5
Electrical connections to voltage and current sources are
3 6 0,75
made with appropriate joints and wires of cross-sections 6 10 1
specified in the table aside. 10 16 1,5
16 25 2,5
While mounting relays on printed boards, the openings on the 25 32 4
board must match the raster of the relay terminals and have 32 40 6
appropriate diameter, which shall enable its easy connection. 40 63 10
Otherwise, terminals may be bent, contacts deformed or the
cover tightness may be disturbed. Printed paths from the relay
contacts should be as wide as possible, which results in lower Fig. 29. Typical rasters of terminals of miniature relays
losses in the course of current flow and good removal of heat
from the contacts. For the purpose of providing good insulation
2,5 mm raster 3,2 mm raster
strength, it is necessary to arrange the circuits appropriately
on the board and to apply protection mask. A 2,5 2,5 B 3,2 3,2

3,5 mm raster 5 mm raster

C 3,5 3,5 D 5 5

5 mm raster
22.02.2018

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The table shows various limiting currents of printed circuits of different thickness of the copper layer and with various con-
ducting paths.

Load Width of the copper printed path [mm]

current Copper thickness 70 µm Copper thickness 35 µm
[A] Single-side Double-side Single-side Double-side
path path path path
16 8 5 inadmissible inadmissible
14 6,5 4 inadmissible inadmissible
12 5 3 7,5 5
10 3,5 2 6 4
8 2,5 1 4 2,5
6 1,5 is not applied 2,5 1,5
4 1 is not applied 1,5 1
2 0,7 is not applied 1 is not applied

International standards

Relays manufactured by Relpol S.A. are designed and tested EN 61812-1 Adjustable time relays for industrial purposes
in compliance with the requirements of the following interna­ - Requirements and tests.
tional standards:
EN 61131-2 Programmable controllers. Part 2: Requirements
EN 61810-1 Electromechanical non-specified time all-or- and equipment tests.
nothing relays. Part 1: General requirements.
Plug-in sockets manufactured by Relpol S.A. are designed
EN 61810-7 Electromechanical elementary relays. Part 7: Test and tested in compliance with the requirements of the following
and measurement procedures. international standard:

EN 60664-1 Insulation coordination for equipment within low- EN 61984 Connectors - Safety requirements and tests.
-voltage systems. Part 1: Principles, requirements and tests.

Insulation

The classification of insulation groups to define the properties At present, while dimensioning the insulation distances in
of insulation of the device in compliance with the insulation accordance with the EN 60664-1 Standard, the overvoltage
coordination was previously done according to the VDE 0110 category and the ambient pollution degree must be defined. The
Standard. latter indicates the expected pollution of the micro­environment.
Electric devices were classified in insulation categories A, B, The transient overvoltage values are the basis for defining the
C or D due to their application and possible reduction of the rated surge voltage which determines the minimum contact
insulation properties caused by the impact of the environment, clearance related with the insulation coordination.
i.e. dust, humidity, aggressive gases, insulation clearance and
creepance. The following overvoltage categories are defined:
The insulation category was indicated together with the refe­ IV - devices at the front of the installation,
rence voltage which was the basis for defining of the require- III - devices in fixed installation in cases where reliability and
ments related to the insulation distances for rated voltage up availability of the device is subject to special requirements,
to the reference voltage value. II - receiving devices supplied from the fixed installation,
I - devices connected to circuits where measures have been
taken (either in fixed installation or in the equipment) to
limit transient overvoltage to the appropriately low level.
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 Relays
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Four pollution degrees have been defined to estimate the 3 - conductive pollution or dry and non-conductive pollution
contact creepance and clearance: occurs which may become conductive due to conden­
1 - no pollution or only dry and non-conducting pollution; the sation,
pollution has no effect, 4 - the pollution proves constant conductivity caused by the
2 - only non-conducting pollution occurs; the vapor conden­ conductive dust, rain or snow.
sation, however, may be expected to cause temporary
conductivity of the pollution from time to time,

The rated surge voltage is defined on the basis of the overvoltage category and the rated voltage of the device.

Rated surge voltage

The rated voltage of the supply Phase voltage
system according to PN-IEC 60038 defined on the basis
of AC or DC Overvoltage category
nominal voltages
up to the value of I II III IV
Three-phase Single-phase

120-240 150 800 1500 2500 4000

230/400 300 1500 2500 4000 6000

The insulation creepance are dimensioned on the basis of Insulation materials are divided into four groups with refe­
the following factors: rence to the value of the indicator of resistance to creeping
- root-mean-square value of rated voltage, current:
- pollution degree, Group I 600 ≤ CTI
- group of insulation materials. Group II 400 ≤ CTI ≤ 600
Group IIIa 175 ≤ CTI ≤ 400
Group IIIb 100 ≤ CTI ≤ 175

Insulation materials testing

1. Glow wire test 2. Ball pressure test
The test simulates exposure to heat originating from such heat The purpose of the test is to assess the resistance of the ma-
sources as glowing parts or overloaded subassemblies in order terial to mechanical pressure at higher temperature with no
to assess fire hazard. significant deformations.
The consistency with the requirements for resistance to heat The test is performed in a heating chamber at higher tempe-
and fire is checked in glow wire test at the temperature of rature, where a steel ball of 5 mm diameter is pressed to the
650 °C. surface of the sample with the force of 20 N. The diameter of
Some applications of the relay extort more strict requirements. the indentation shall not exceed 2 mm. The test is made under
The EN 60335-1 Standard: ”Household and similar electrical EN 60695-10-2 Standard.
appliances”, provides that the insulation parts supporting ele-
ments which conduct current higher than 0,2 A must meet the 3. Resistance to proof tracking
following requirements as for resistance to fire: The test shows relative resistance of solid insulation materials
a) GWFI (Glow Wire Flammability Index) with a value 850 °C to proof tracking for voltages up to 600 V when the surface of
according to the EN 60695-2-12 Standard. the insulation, at electrical tension, is exposed to contaminated
b) GWIT (Glow Wire Ignition Temperature) with a value 775 °C water.
according to the EN 60695-2-13 Standard. Proof tracking is probable between parts of different potential
and between live parts and earthed metal parts.
Compliance with the requirements is checked under the EN
60112 Standard for PTI index.
In case the type of the relay application requires more strict
22.02.2018

requirements, PTI 250V, PTI 400V or PTI 600V proof tracking

resistance indices shall be assumed.

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 Relays
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Electromagnetic compatibility

Electromagnetic compatibility is the ability of an electric or An electromagnetic relay may initiate disturbances, particularly
electronic appliance to operate correctly in a given electroma- when operating with inductive load of contacts. An electric arc
gnetic environment and not to emit disturbances not tolerated occurring while switching, and overvoltage cause emission
by other appliances which operate in the same environment. of disturbances which may affect the operation of a sensitive
The relay is insensitive to high frequency disturbances but electronic appliance in the proximity of the relay. In such ca-
presence of high power electromagnetic fields in the proximity ses, circuits of protection of contacts shall be applied, which
of the relay coil may affect making and releasing voltages of will allow decreasing the level of disturbances to a safe level.
the relay. On installation of a relay in the proximity of transfor- Relays, as components, are not covered with the EMC Direc-
mers, electromagnets and electric motors, it is recommended tive. However, each electric appliance which includes relays
to check making and releasing of the relay. is covered with the Directive and subject to its requirements.

EMC test Standard

Resistance to electrostatic discharges EN 61000-4-2
Resistance to electromagnetic field of radio frequency EN 61000-4-3
Resistance to quick pulse beams EN 61000-4-4
Resistance to surges EN 61000-4-5
Resistance to conductive disturbances induced by fields of radio frequency EN 61000-4-6
Resistance to voltage dips, short breaks and changes EN 61000-4-11
Measurements of radiated and conducted emissions EN 55011

The most frequent disturbances in installations are quick, inductive loads - electromagnets, motors, etc. They have the
repeatable transient states - beams of electric disturbances form of a beam of high voltage and low power pulses, as the
called BURST. These are transient disturbances occurring in pulse increment time is merely 5 ns and its duration is 50 ns.
supply, signal and control connections. They origin from tran- In tests the duration of a pulse beam is defined as 15 ms, and
sient switching states and occur on switching by the contact of the period - 300 ms.

300 ms
15 ms
50 ns

5 ns

Another type of disturbances occurring frequently, due to at-

mospheric discharges, in low voltage installations are surges
(SURGE) in supply lines. Similar disturbances may be also 100
caused by connection processes of high power, e.g. switching 90
of leading loads, etc. Relative
Surge pulses are of definitely higher power than burst pulses value of
due to much longer duration - 50 µs. voltage Peak value
50

30

0
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0 1,2 50
Time [ms]

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 Relays
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Protection against ambient effect

As for the protection from ambient effect, the EN 61810-7 Cover protection degrees according to EN 60529 Standard.
Standard distinguishes the following types of relays: The first digit refers to the protection from foreign solids pene­
tration. The second digit refers to the protection from water
RT0 - open relay - a relay without protective cover. penetration.

RTI - dust protected relay - a relay with cover to protect its Examples of indications:
mechanism from dust. IP 20 - protection against solids of the diameter of 12,5 mm
and larger, with no protection against water penetration.
RTII - flux proof relay - a relay adapted to automatic soldering IP 40 - protection against penetration of solids of 1 mm
process without allowing the migration of solder fluxes diameter and larger, with no protection from water
beyond the intended areas. penetration.
IP 50 - protection against dust; dust penetration is not excluded
RTIII - washable relay - a relay adapted to automatic soldering entirely but dust shall not penetrate in quantities which
process and then subject to washing process for the might disturb correct operation of the appliance or
purpose to remove flux residues without allowing the reduce safety.
ingress of flux or washing solvents. Note: the relays IP 64 - dustproof protection, protection against water splashes
shall not be washed in ultrasonic cleaners. RTIII relay - water splashed onto the cover from any direction does
are tested to evaluate sealing acc. to EN 60068-2-17, not cause harmful effects.
Qc test. IP 67 - dustproof protection, protection against the effects of
momentary submersion in water.
RTIV - sealed relay - relay provided with a case which has
no venting to the outside atmosphere and having
a time constant better than 2 x 104 s in acc. with EN
60068-2-17.

RTV - hermetic relay - a tight relay of enhanced tightness level,

in a metal cover, terminals sealed with glass, gas-filled.

Ambient conditions

Storage and use of the relays is not allowed in the conditions Climatic resistance:
which may cause steam condensation and/or icing. Cold: 16 h at minimum temperature defined for the product
The relays shall be stored and used at temperatures specified according to the Standard EN 60068-2-1.
in catalog cards of individual products. Dry heat: 16 h at maximum temperature defined for the product
Admissible relative humidity for storage and operation within according to the Standard EN 60068-2-2.
the range of 5...85% (with no condensation and/or icing). Humid heat: 2 cycles 12 h each at temperature of +25...+55 °C
Atmospheric pressure: 86...106 kPa and at humidity 90...95%, according to the Standard EN
60068-2-30.
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 Relays
basic information

Electric load

Electromagnetic auxiliary relays manufactured by Relpol S.A. Contact application categories according to EN 61810-7
are designed for a wide range of applications and for switching Standard
several loads of diversified characteristics.
Electric loads are classified according to their nature (resisti- Application Voltage Current
ve, capacitive or inductive loads), type of supply (DC or AC), category [V] [A]
load value and the current curve course shape (lamp, motor, 0 (CA 0) < 0,03 < 0,01
electromagnetic, etc. loads).
1 (CA 1) 0,03 < U < 60 0,01 < I < 0,1
2 (CA 2) 5 < U < 250 0,1 < I <1
3 (CA 3) 5 < U < 600 0,1 < I < 100

Application categories according to EN 60947-4-1 and EN 60947-5-1 Standards

Application category Typical application

AC-1 Resistive or slightly inductive loads, resistance furnaces

AC-2 Slip-ring motors: start-up, switching off
AC-3 Squirrel-cage motors: start-up, switching off motors during running time
AC-4 Squirrel-cage motors: start-up, reversing (countercurrent braking), pulsing
AC-5a Discharge lamps
AC-5b Electric bulbs
AC-6a Transfomers
AC-6b Capacitor banks

Application categories according to EN 60947-4-1 and EN 60947-5-1 Standards

Application category Typical application

AC-7a Slightly inductive loads in household appliances and similar applications

AC-7b Motors in household appliances
AC-8a Hermetic refrigerant compressor motors with manual overload resetting
AC-8b Hermetic refrigerant compressor motor control with automatic overload resetting
AC-12 Control of resistive loads and solid state loads with opto-isolators
AC-13 Control of solid state loads with transformer isolation
AC-14 Control of small electromagnetic loads (≤ 72 VA)
AC-15 Control of AC electromagnetic loads (> 72 VA)
DC-1 Resistive or slightly inductive loads
DC-3 Shunt-motors: start-up, breaking
DC-5 Series-motors: start-up, countercurrent braking, pulsing. Dynamic switching-off of DC motors
DC-6 Bulbs
DC-12 Control of resistive loads and solid state loads with opto-isolators
DC-13 Control of DC electromagnets
DC-14 Control of DC resistive loads having economy resistors in the circuit
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 Relays
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Certifications

Compliance with national and international standards provides tion (CENELEC), and international standards set forth by the
for safe use of the product, and proves high quality and du- International Electrotechnical Commission (IEC).
rability of the product. In some countries (e.g. USA, Canada, The products manufactured and offered by Relpol S.A. have
Russia), the product certification to prove its compliance with numerous certifications issued by renowned research institu-
the requirements of appropriate national standards is obligatory, tions such as VDE, UL or CSA International
and the product must undergo the procedure of compliance The electromagnetic relays have been certified to comply with
assessment at certifying agencies in order to be approved for the following standards: EN 61810-1 - VDE, UL 508 - Under­
sale. In other countries it is the manufacturer’s responsibility writers Laboratories, C22.2 - CSA International, GB14048.5
to provide the compliance of the design and production with - China Quality Certification Centre.
the requirements of appropriate standards (e.g. the countries Apart from the certifications which prove the safety and high
of the European Union). durability of the products, some of Relpol’s products have
Certification agencies carry out the testing procedure in accor- certifications required for applications of relays in special con-
dance to applicable standards, and then they regularly audit the ditions, e.g. Lloyd’s Register certification which acknow­ledges
production process in order to confirm that the require­ments compliance with the requirements for electrotechnical products
are observed in current production of the certified product. The to be used on vessels and in devices which operate in adverse
European Union applies European Standards (EN) as set forth climatic conditions, or certificates of AUCOTEAM GmbH, Berlin
by the European Committee for Electrotechnical Standardiza- or Railway Institute to confirm meeting of railway requirements.

22.02.2018

PRECAUTIONS:
1. Ensure that the parameters of the product described in its specification provide a safety margin for the appropriate operation of the device or system and never use
the product in circumstances which exceed the parameters of the product. 2. Never touch any live parts of the device. 3. Ensure that the product has been connected
correctly. An incorrect connection may cause malfunction, excessive heating or risk of fire. 4. In case of any risk of any serious material loss or death or injuries
of humans or animals, the devices or systems shall be designed so to equip them with double safety system to guarantee their reliable operation.

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