Keysight Technologies

Maximizing the Life Span of Your Relays

Application Note

This application note is for automated

test engineers and engineers who use a
datalogger for R&D or production testing.
In it, you will find information that will
help you select the right relays for your
switching application, realistically predict
the longevity of your relays, and prevent
early failures.
Introduction

Electromechanical relays can be used as actuators, as switches to route power to electrical devices, or for signal
routing within a device or between different instruments. In data acquisition applications, relays are used to connect
multiple transducers to a single measuring device.

Most electromechanical relays are driven electromagnetically. A magnetic flux is generated by passing current
through a coil. This magnetic flux causes an armature to move, and the movement causes isolated electrical
contacts to open or close, thus making or breaking electrical connections.

As with all mechanical devices, relays eventually wear out. If you use the right relays for the type of
measurements you are making and derate them appropriately, you can protect your relays against early failure and
prevent damage to your test instruments.

34901A multiplexer module using armature switch relays 34902A multiplexer module using Reed switch relays
03 | Keysight | Maximizing the Life Span of Your Relays - Application Note

Selecting the right relay

Selecting the correct relay for your application is critical to the longevity of your relays.
Four types of relays are commonly used in switching and signal routing; each offers
distinct advantages and disadvantages, and each works best for certain applications.

Reed relays
When you need to switch at high speeds, reed relays typically are a good choice. In
general, reed relays switch much faster than armature relays, have very low contact
resistance and offer the added benefit of being hermetically sealed. They do not have the
capacity to carry as high voltages and currents as armature relays.

Mercury-wetted relays
Mercury-wetted relays have long lives, don’t suffer from contact bounce, and have very
low contact resistance. However, they are position-sensitive, and must be mounted in
the correct orientation to operate properly. Environmental concerns about mercury have
limited the popularity of mercury-wetted relays.

Armature relays
Because of their ruggedness and ability to handle higher currents and voltages,
armatures are the most commonly used relays. Armature relays usually have low
resistance. They generally have slower switch times, and they are somewhat more
susceptible to arcing than the other types. Some armature relays are sealed; others are
not.

Solid-state relays
Solid-state relays typically are used for switching highpower circuits, such as ac line
voltages. Solid-state relays have no moving parts and are arc-free. However, they
generally have a higher “on resistance” than is acceptable in low-level signal switching
applications.
04 | Keysight | Maximizing the Life Span of Your Relays - Application Note

Table 1 summarizes general characteristics of the different relay

types.

Table 1. Relay characteristics

Relay type
Reed Mercury-wetted Armature Solid-state
Contact resistance Very low Very low Low High
Switch speed 1000/s 100/s 50/s 1,000/s
Life 10 million 10 million 1 million Infinite
Typical failure mode Fails open Fails open Fails open Fails shorted
Typical max. input 100 V/100 mA 100 V/100 mA 250 V/2 A 250 V/10 A
Use for High-speed, low-level Not recommended Low-level switching with High-power circuits
switching applications because of environmental higher currents and voltages
concerns

Predicting relay life spans Capacitive loads

Capacitors resemble short circuits when they are charging, so the
Relay manufacturers specify how long their relays will last, but in-rush current from a capacitive load can be very high. Series
the expected lifetime will vary depending on the loads they are resistors are often used to limit in-rush current; without a limiting
subjected to. For resistive loads, manufacturers’ specifications resistor, contact welding may occur. When you are switching
are typically fairly accurate. On the other hand, if you are using capacitive loads, you typically will want to derate your relay to 75
capacitance or inductance, your relay life span will be shorter percent of the resistive rating.
than the manufacturers specification. How much shorter depends
on the type of loads you are switching. Derating gives you a
realistic picture of how long your relay will last.
Motor loads
When an electric motor starts up, it has very low impedance
Loads can be classified into five general groups. and requires a large in-rush current to begin building a magnetic
field and begin rotating. Once it is running, it generates a back
Resistive loads electromagnetic force (emf), which can cause a large inductive
spike when the switch is opened. The result is a large in-rush
Relay manufacturers assume you will be using resistive loads current at “turn-on” and arcing at “turn-off.” When you are
when they rate their relays. The load is a simple resistive element, switching a motor load, typical industry practice is to derate to 20
and it is assumed that the current flow through the contacts percent of the resistive rating.
will be fairly constant, although some increase may occur due
to arcing during “make” or “break.” Ideally, a relay with a purely
resistive load can be operated at its stated voltage and current
Incandescent loads
ratings and attain its full lifetime. Industry practice, however, is to An incandescent lamp is considered a resistive load. However,
derate to 75 percent of the relay’s stated capacity. the resistance of a hot tungsten filament is 10 to 15 times greater
than its resistance when it is cold. The high in-rush current into
Inductive loads a cold filament can easily damage relay contacts. When you are
switching incandescent loads, you will want to derate relay values
Switching inductive loads is difficult, primarily because current to 10 percent of the resistive load rating. When possible, consider
tends to continue to flow in inductors, even as contacts are being placing a current-limiting resistor in series with the filament to
broken. The stored energy in inductors induces arcing; arc-sup- limit this in-rush current.
pression schemes are frequently used. When you are switching
inductive loads, you typically will want to derate relay contacts to
40 percent of the resistive load rating.
05 | Keysight | Maximizing the Life Span of Your Relays - Application Note

Table 2 summarizes relay switch derating factors based on the RC protection networks
type of load switched:
When you design RC protection networks, you select the
protection resistor (Rp) as a compromise between two resistance
Table 2. Relay derating factors for common load types
values. The maximum acceptable relay contact current (Imax)
determines the minimum value of Rp. If you assume the maximum
Type ofload Percent of rated value allowable relay current (Imax) is 1 A dc or ac rms, the minimum
Resistive 75 value for Rp is V/Io, where V is the peak value of the supply
Inductive 40 voltage.
Capacitive 75 V V
Rp = =
Motor 20 Imax 2
Incandescent 10
Usually, the maximum value for Rp is made equal to the load
resistance (RL). Therefore, the limits on Rp can be stated as:
Prolonging relay life V
<R <R
Over time, your switching system typically accumulates a large Imax p L
number of switch closures, so prolonging relay life is important.
The most common relay types—with the exception of solidstat The actual value of the current (Io) in a circuit is determined by the
relays—rely on the mechanical closing of metal-based contacts equation:
that are covered with a thin surface film. As these electrical
V
contacts are closing, a large electrical field is generated between Io =
RL
them, which can initiate an arc. An arc also can form when
these contacts open. This is particularly true if the load you are
where V is the peak value of the source voltage, and RL is the
switching is inductive. Arcing, and the welding of contacts that is
resistance of the load. You will use the value for Io to determine
associated with it, affects relay contact reliability and life span.
the value of the protection capacitor (Cp).
Other factors that affect contact reliability and life include the
types of loads being switched, highpower or high-voltage
You need to consider several factors when you want to determine
switching, the heat capacity and thermal resistance of the
the value of the protection network capacitor (Cp). First, the total
contacts themselves, and the surrounding ambient temperature.
circuit capacitance (C tot) must be such that the peak voltage
across the open relay contacts does not exceed the maximum
The maximum voltage, current, and power specifications of the
voltage rating of the relay. For a rating of 300 Vrms, the equation
relay contacts must be within the expected signal levels being
for determining the minimum allowable circuit
switched. Switch contacts often can carry more energy than they
capacitance is:
can break at a switching point. In all cases, your contacts will last
longer if you switch lower energy. C tot> (Io /300)2 x L

where L is the inductance of the load, and Io is the current value

Suppression circuits
calculated earlier.
As we mentioned earlier, you may want to limit the surge current
into the relay contacts. Whenever a relay contact opens or closes, The total circuit capacitance (C tot) is made up of the wiring
electrical breakdown or arcing can occur between the contacts. capacitance plus the value of the protection network capacitor
Arcing can cause high-frequency noise radiation, voltage and Cp. Therefore, the minimum value for Cp should be the value
current surges, and physical damage to the relay contacts. For obtained for the total circuit capacitance (C tot). The actual
capacitive loads, you can use a simple resistor, inductor, or value used for Cp should be substantially greater than the value
thermistor in series with the load to reduce the in-rush current. calculated for C tot.
For inductive loads, you can use techniques to clamp the voltage.

You also can place clamps, a diode, a zener diode, a varistor, or

a resistor/ capacitor (RC) network in parallel with the load as a
snubber or suppression circuit. In the next section, we’ll take a
closer look at RC networks and varistors (Figure 1).

Figure 1. Suppression circuit for limiting surge voltage

06 | Keysight | Maximizing the Life Span of Your Relays - Application Note

Prolonging relay life (continued)

Using varistors
Use a varistor when adding an absolute voltage limit across the
relay contacts. Varistors are available for a wide range of voltage
and clamp energy ratings. Once the circuit reaches the varistor’s
voltage rating, the varistor’s resistance declines rapidly. A varistor
can supplement an RC network, and is especially useful when the
required capacitance (Cp) is too large.

Conclusion
You can maximize your relay’s potential life if you choose the
correct relay type, if you keep voltage, current and power ratings
within the relay’s ratings (derated as appropriate for a given load
type), and if you add snubber circuits as required.

To learn more, go to www.Keysight.com/find/daq

References
Keysight 34970 Data Acquisition and Control Unit Users Manual
Electronic Engineer’s Reference Book, Edited by FF Mazda
Electronic Engineer’s Handbook, Fourth Edition, Donald
Christiansen

Glossary
Derate—lowering the manufacturer’s ratings for a relay based on
the load type
Snubber circuit—same as suppression circuit
Suppression circuit—a circuit used to limit the surge current into
relay contacts
Varistor—a protective device used on low-voltage ac circuits to
limit transient overvoltages and divert transient currents
Zener diode—a device used as a voltage regulator

Related Keysight Literature

Product Overview—34970A Data Acquisition/Switch Unit, pub.
no. 5965-5290EN
07 | Keysight | Maximizing the Life Span of Your Relays - Application Note

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This document was formerly known as application note number 1399 (BP-9-7-17)

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© Keysight Technologies, 2002 - 2014, 2017
Published in USA, December 1, 2017
5988-6917EN
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