2 RELAYS - GENERAL

2.1 Relay technology

The relay was invented more than 160
years ago. During the last 50 years it has
undergone considerable change, the most
obvious of which is its reduction in size.
Using new and advanced contact
materials, the switching capacity has either
been maintained or increased and the use
of new plastic materials has improved the
insulation
properties.
State-of-the-art
technology and precision engineering has
led to increased relay sensitivity, i.e. the
ratio of input coil power to switching
capacity.
Typical applications for relays include laboratory
instruments,
telecommunication
systems, computer interfaces, domestic
appliances, air conditioning and heating, automotive electrics, traffic control, lighting
control, building control, electric power control, business machines, control of motors and
solenoids, tooling machines, production and test equipment.
fig 2.1

Relay Innovation

2.2 Relay functions

Relays are electromagnetically operated switches. An actuating current on a coil operates
one or more galvanically separated contacts or load circuits.
The electromechanical relay is a remote controlled switch capable of switching multiple
circuits, either individually, simultaneously, or in sequence.
The primary function of a relay is:
the galvanic separation of the primary or actuating circuit and the load circuits
single input/multiple output capability
separation of different load circuits for multi-pole relays
separation of AC and DC circuits
interface between electronic and power circuits
multiple switching functions, e.g. delay, signal conditioning
amplifier function.

POWER RELAYS

The capability to operate the power contacts and switch high currents with low input power
on the primary side provides the amplifier function of the relay. However, unlike the
transistor, the relay is not an analog amplifier but a "digital" (0-1, ON-OFF) type amplifier.
Input signals can be amplified by a factor up to 105 or reduced as in signal relay
applications.

fig 2.2

Transistor Characteristic

fig 2.3

Relay Characteristic

2.3 Relay classification

Relays have the same subsystems and
principals of operation regardless of
whether they are electromechanical or
electronic, or designed to switch signal or
high power loads.
These principle functions are:
conversion of an electrical input signal
on the primary side to an intermediate
and non electric physical signal
reconversion of this non electric physical
signal to operate a switching element
(secondary side) such as contacts which
switch and conduct electrical current
(output, load current)
the use of the non electric signal
between primary and secondary side
provides
the
necessary
galvanic
separation between input and output circuits.
4

fig 2.4

Relay

RELAYS - GENERAL

These basic relay functions can be achieved in very different ways. The resulting variety of
designs are classified in several groups:
Electromechanical relays - Electronic relays
According to the nature of the secondary switching element, basic relay types are:
Electromechanical relays
In this case the switching element is a
mechanical contact. This is the most widely
used type of relay design. Standard yoke
type designs as well as reed relays and
others are part of this group. The principal
internal functions of the electromechanical
relay are:
conversion of electrical current (input,
coil current) to a magnetic field
conversion of the magnetic field into a
mechanical force
this force operates the contacts
(secondary side)
contacts switch and conduct electrical
current (output, load current).
fig 2.5

Electromechanical Relay

Electronic relays
This type of relay uses electronic switches such as transistors, triacs, etc. as the main
switching element.
Electromagnetic relays - other designs
Relays can also be classified according to the nature of the intermediate signal between the
primary side and the switching element. For example:
Electromagnetic relays
A magnetic field generated by the input signal operates on the mechanical contacts.
Examples are the standard yoke type relay or the reed relay.
Optocouplers
In this type of "relay" the electronic switching element is controlled optically. On the primary
side an optical signal is transmitted by means of a light emitting diode, while a
phototransistor acts as a receiver and controls the switching element. In this case the optical
connection provides the galvanic separation.

POWER RELAYS

Other electronic designs

The signal from the primary side also can be transmitted by other means, e.g. by frequency
modulation or capacitive effects. These are techniques used by solid state relays.
Other more exotic relay designs are:
Thermo-electric relays
The input energy on the primary side heats a bimetal part which actuates the contacts
mechanically.
Piezo relays
In this type of design the contacts are operated mechanically by the piezoelectric effect.
Signal relays - Power relays - Contactors
Relay designs can also be divided according to their switching capacity i.e.
Signal relays
Signal switching relays cover signal, data
and voice switching applications up to
approximately 2A resistive load. Typical
applications are measurement systems,
computer interfaces and telecommunications. Designs for signal relays include
standard yoke type relays, reed relays and
solid state relays.
Power relays
According to IEC 255, these are relays
which switch up to 600V and 100A. The
high current area overlaps the switching
range of contactors.
fig 2.6

Power Relays

In this book the term "POWER RELAY" covers

relays switching resistive and inductive loads
up to 30A.

RELAYS - GENERAL

Generally, power relays switch up to 16A for PCB types and up to 30A for industrial types.
The most common design for power relays is the standard yoke type relay. For some
applications solid state power relays may be used (see chapter 10).
Contactors
Although contactors are not strictly relays they have the same design principles. Like relays,
they are remote controlled switches. The difference is the considerably higher input power
consumption, higher switching capacity, and larger size.
Miniature, PCB, industrial relays etc.
Power relay types can also be divided according to their mechanical features i.e. miniature,
PCB, industrial etc.
The term miniature refers to physical size. However, as relay technology has used this term
for some time it does not necessarily give an indication of absolute size.
PCB power relays are designed for mounting on printed circuit boards.
Industrial relays are typically used in switching cabinets by control panel builders.
As you can see, there is a wide range of different electromechanical relay types to suit
almost all applications. However, having such a large choice can make selection difficult.
Design principles throughout the different relay classifications are the same and basic
characteristics and technological aspects are interchangeable.

This book concentrates on the characteristics of

POWER RELAYS and their background according
to the above definition.