general information related documents... · 2008-04-04 · general information 4 contact protection...

G E N E R A L I N F O R M A T I O N


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General Information

Straight PCB terminalPCB terminals are normally straight.

Curved-tail (S-shaped)PCB terminalSome relays have terminals that are bentinto an “S” shape. This secures the PCBrelay to the PCB prior to soldering,helping the terminals stay in their holes,keeping the relay level.

Built-in diodeA diode is built into some relays, wired inparallel with the coil to absorb thecounterelectromotive force (counter emf)generated by the coil.

Operation indicatorSome relays are provided with a light-emitting diode (LED), wired in parallelwith the coil. This permits a fast-check ofthe relay’s operating status.

Quick-connect terminal

Quick-connect/PCB terminal

Plug-in terminal

Gull-wing SMT terminal

“Inside L” SMT terminal

Dimensions

Mounting orientation markOn top of all OMRON relays is a markindicating where the relay coil is located.Knowing the coil location aids in design-ing PC boards when spacing compo-nents. Also, pin orientation is easy todiscern when automatic or hand-mounting relays.

Terminal arrangement/InternalconnectionsTop viewIf the terminal arrangement of a relay canbe seen from above the PCB, the topview of the relay is provided in the“Dimensions” section of the catalog ordata sheet. This example shows DIP-stylerelay terminals, which are visible evenwhen the relay is mounted.

On dimensional drawings in all OMRON literature this mark is left-oriented. Mountingholes, terminal arrangements, and internal connections follow this alignment. Thefollowing two symbols are used to represent the orientation mark:

DrawingView Bottom Top

Detail Mounting holes Terminal arrangement/Internalconnection

Symbol

Example

Bottom viewHowever, if the relay terminal cannot beseen from above the PC board, as in thisexample, a bottom view will be shown.

Rotation direction to bottom viewThe bottom view shown in the catalog ordata sheet is rotated in the directionindicated by the arrow, with the coilalways on the left.

(bottom view) (bottom view)

Options


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Contact Information

Carry currentThe value of the current which can becontinuously applied to the relaycontacts without opening or closingthem, and which allows the relay to staywithin the permissible temperature riselimit.

Contact formThe arrangement of contacts on a relay.Form A: SPST-NOForm B: SPST-NCForm C: SPDT - B -M

Contact resistanceThe total resistance of the conductor, aswell as specific resistivities such as ofthe armature and terminal, and theresistance of the contacts. (This value isdetermined by measuring the voltagedrop across the contacts by allowingtest current as shown in the table):

Rated current (A) Test current (mA)Under 0.01 10.01 to 0.1 100.1 to 1 100

Over 1 1000

For most applications, use at least 1 A,5 VDC for contact resistance measure-ments.

Contact symbols

NO NC DT

Double-break NC

Make-before-break Latching relays

Make-before-breakA contact arrangement in which part ofthe switching section is shared betweenboth an NO and an NC contact. When therelay operates or releases, the contactthat closes the circuit operates before thecontact that opens the circuit releases.Thus both contacts are closed momen-tarily at the same time.

Maximum switching capacityThe maximum value of the load capacitywhich can be switched without a problem.When using a relay, be careful not toexceed this value.

For example, when switched voltage V1 isknown, maximum switched current I1 canbe obtained at the point of intersection onthe characteristic curve “Maximumswitching capacity” shown below. Con-versely, maximum switched voltage V1 canbe obtained if I1 is known.

Maximum operating current (I1) =

Maximum switching capacity [W(VA)]Operating voltage (V1)

Maximum operating current (V1) =

Maximum switching capacity [W(VA)]Operating current (I1)

For instance, if operating voltage = 40 V,maximum operating current = 2 A (seecircled point on graph)

The life expectancy of the relay can bedetermined from the “Electrical servicelife” curve, based on the rated operatingcurrent (I1) obtained above.

For instance, the electrical service life atthe obtained maximum operating currentof 2 A is slightly over 300,000 operations(see circled point on following graph).

Electrical service life

However, with a DC load, it may becomedifficult to break the circuit of 48 V or moredue to arcing. Determine suitability of therelay in actual usage testing. Correlationbetween the contact ratings is shown inthe following figure:

Minimum permissible loadThe minimum permissible load indicatesthe lower limit of the switching capability ofthe relay. Such minute load levels can befound in microelectronic circuits. Thisvalue may vary, depending on operatingfrequency, operating conditions, expectedreliability level of the relay, etc. It isrecommended to double-check relaysuitability under actual load conditions. Inthis catalog, the minimum permissible loadof each relay is indicated as a referencevalue. It indicates failure level at areliability level of 60% (λ60).λ60 = 0.1 x 10-6/operation means that onefailure is presumed to occur per10,000,000 (ten million) operations at thereliability level of 60%.

Number of polesThe number of individual contact circuits.



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ApplicabilityCircuit example

AC DCFeatures and remarks Element selection

RC Fair* Good

Good Good

Diode NA Good

Optimum C and R values are:C: 1 to 0.5 µF for 1 A contact currentR: 0.5 to 1 Ω for 1 V contact voltageThese values do not always agree with theoptimum values due to the nature of theload and the dispersion in the relaycharacteristics. Confirm optimum valuesexperimentally. Capacitor C suppressesdischarge when the contacts are opened,while resistor R limits the current appliedwhen the contacts are closed the next time.Generally, employ a capacitor C whosedielectric strength is 200 to 300 V or morethan double the switching voltage. If thecircuit is powered by an AC power source,employ an AC capacitor (non-polarized).

Employ a diode having a reverse break-down voltage of more than 10 times thecircuit voltage, and a forward current ratinggreater than the load current. A diodehaving a reverse breakdown voltage two tothree times that of the supply voltage canbe used in an electronic circuit where thecircuit voltage is not particularly high.

Contacts

The contacts are the most importantconstituent of a relay. Their characteris-tics are significantly affected by factorssuch as the material of the contacts,voltage and current values applied tothem (especially, the voltage and currentwaveforms when energizing and de-energizing the contacts), the type of load,operating frequency, atmosphere, contactarrangements, and bounce. If any ofthese factors fail to satisfy a predeter-mined value, problems such as metaldegradation between contacts, contactwelding, wear, or a rapid increase in thecontact resistance may occur.

Contact Voltage and CurrentVoltage (AC, DC)When a relay breaks an inductive load, afairly high counterelectromotive force(counter emf) is generated in the relay’scontact circuit. The higher the counter

emf, the greater the damage to thecontacts. This may result in a significantdecrease in the switching capacity of theDC-switching relay. This is because,unlike the AC-switching relay, the DC-switching does not have a zero-crosspoint. Once arc has been generated, itdoes not easily diminish, prolonging thearc time. Moreover, the unidirectional flowof the current in a DC circuit may causemetal degradation to occur betweencontacts and the contacts to wear rapidly(this is discussed later).

If the voltage applied to the DC-operatedcoil increases or decreases slowly, eachcontact of a multi-pole contact relay maynot operate at the same time. It is alsopossible for this situation to result in thepickup voltage varying each time therelay operates. Either way, circuitsequencing will not be correct. In criticalapplications, the use of a Schmitt circuit

Contact Information

is recommended, used to reshape the DCwaveform to trigger all contacts of therelay at the same time.

Despite the information a catalog or datasheet sets forth as the approximateswitched power of the relay, alwaysconfirm the actual switched power byperforming a test with actual load.

CurrentThe quality of electrical current whichflows through the contacts directlyinfluences the contacts’ characteristics.For example, when the relay is used tocontrol an inductive load such as a motoror tungsten load such as a lamp, thecontacts will wear faster, and metaldecomposition between the matingcontacts will occur more often as theinrush current to the contacts increases.Consequently, at some point the contactsmay weld.

Contact Protection Circuit

A contact protection circuit, designed toprolong the life expectancy of the relay isrecommended. This protection will havethe additional advantage of suppressing

noise, as well as preventing the genera-tion of carbon at the contact surfacewhen the relay contact is opened.However, unless designed correctly, the

protection circuit may produce adverseeffects, such as prolonging the releasetime of the relay. The following table listsexamples of contact protection circuits:

* Load impedance must be muchsmaller than the RC circuit whenthe relay operates on an ACvoltage.

This circuit is effective if con-nected across the load when thesupply voltage is 24 to 48 V. Whenthe supply voltage is 100 to 240 V,connect the circuit across thecontacts.

The diode protects the coil fromany inductive kickback. Relayswith a diode connected in parallelwith the relay coil tend to experi-ence increased release times.


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Contact Protection Circuit

Contact Information

Avoid use of a surge suppressor in the manner shown below.

This circuit arrangement is very effectivefor diminishing sparking (arcing) at thecontacts, when breaking the circuit.However, since electrical energy isstored in C (capacitor) when the contactsare open, the current from C flowsadditionally into the contacts when theyclose. Therefore, metal degradation islikely to occur between mating contacts.

Although it is thought that switching a DCinductive load is more difficult than aresistive load, an appropriate contactprotection circuit can achieve almost thesame characteristics.

This circuit effectively shortensrelease time in applications wherethe release time of a diode protec-tion circuit proves to be too slow.

By utilizing the constant-voltagecharacteristic of a varistor, this circuitprevents high voltages from beingapplied across the contacts. Thiscircuit also delays somewhat therelease time.This circuit, if connected across theload, is effective when the supplyvoltage is 24 to 48 V. If the supplyvoltage is 100 to 240 V, connect thecircuit across the contacts.

ApplicabilityCircuit example

AC DCFeatures and remarks Element selection

Diode + NA GoodZenerdiode

Varistor Good Good

The Zener diode breakdown voltageshould be about the same as the supplyvoltage.

This circuit arrangement is very useful fordiminishing sparking (arcing) at thecontacts when breaking the circuit.However, since the charging current to Cflows into the contacts when they areclosed, metal degradation is likely tooccur between the mating contacts.



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Coil resistance (applicable toDC-switching type only)The resistance of the coil is measured ata temperature of 23°C with a tolerance of±10% unless otherwise specified. (Thecoil resistance of an AC-switching typerelay may be given for reference whenthe coil inductance is specified.)

Cold startThe ratings set forth in the catalog ordata sheet are measured at a coiltemperature of 23°C unless otherwisespecified.

Maximum voltageThe maximum value of permissible overvoltage in the operating power supply tothe relay coil.

Rated coil voltageA reference voltage applied to the coilwhen the relay is used under normaloperating conditions. The following tablelists the AC rated voltages:

Minimum pulse widthThe minimum width of the pulse voltagerequired to set and reset a latching relayat a temperature of 23°C

Pickup (set pickup) voltageThe threshold value of a voltage at whicha relay operates when the input voltageapplied to the relay coil in the reset stateis increased gradually.

Must dropout (reset pickup)voltageThe threshold value of a voltage at whicha relay releases when the rated inputvoltage applied to the relay coil in theoperating state is decreased gradually.

Power consumptionThe power consumed by the coil (= ratedvoltage x rated current) when the ratedvoltage is applied to it. A frequency of 60Hz is assumed if the relay is intended forAC operation.

The current flows through the coil whenthe rated voltage is applied to the coil ata temperature of 23°C and with atolerance of +15% and –20%, unlessotherwise specified.

Single-side stable type (standard)The contacts of this simple type of relaymomentarily turn ON and OFF, depend-ing on the energized state of the coil.

Terminal arrangement/Internalconnections(Bottom view)

Mounting orientation mark

Dual-winding, latching typeThis latching relay has two coils: set andreset. It can retain the ON or OFF stateseven when a pulsating voltage is supplied,or when the voltage is removed.



S: set coilR: reset coil

Single-winding, latching typeUnlike the dual-winding latching relay,the single-winding latching relay has onlyone coil. This coil serves as both the setand reset coils, depending on the polarity(direction) of current flow. When currentflows through the coil in the forwarddirection, the coil serves as a set coil;when the current flows in the reversedirection, it functions as a reset coil.



S: set coilR: reset coil

Coil Symbols

Set coil

Coil Information

Coils with polarity designations

Reset coil

RatingApplicable power

Inscription on relay Description in catalogsource

Rating 1 100 V 60 Hz 100 VAC 60 Hz 100 VAC 60 Hz

Rating 2100 VAC 50 Hz

100 VAC 100 VAC100 VAC 60 Hz

100 VAC 50 Hz100/110 VAC 60 Hz

Rating 3 100 VAC 60 Hz100 VAC 50 Hz

100/110 VAC110 VAC 60 Hz

100 VAC 50 Hz

Rating 4100 VAC 60 Hz

100/110 VAC 100/110 VAC110 VAC 50 Hz110 VAC 60 Hz


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To guarantee accurate and stable relayoperation, the first and foremost condi-tion to be satisfied is the application ofthe rated voltage to the relay. Addition-ally, details concerning the type of powersource, voltage fluctuation, changes incoil resistance due to temperature riseand the rated voltage must also beconsidered. If a voltage higher than therated maximum voltage is applied to thecoil for a long time, layer short-circuitingand damage to the coil by burning maytake place.

Coil Temperature Rise

When a current flows through the coil,the coil’s temperature rises to a measur-able level, because of copper loss. If analternating current flows, the temperaturerises even more, due not only to thecopper loss, but to the iron loss of themagnetic materials, such as the core.Moreover, when a current is applied tothe contacts, heat is generated on thecontacts, raising the coil temperatureeven higher (however, with relays whosecontact current is rated at 2 A or lower,this rise is insignificant).

Temperature Rise byPulsating Voltage

When a pulsating voltage having an ONtime of less than 2 minutes is applied tothe relay, the coil temperature rise varies,and is independent of the duration of theON time, depending only on the ratio ofthe ON time to the OFF time. The coiltemperature in this case does not rise ashigh as when a voltage is continuouslyapplied to the relay.

RelativeEnergizing time temperature

rise (%)

Continuously energized 100

ON: OFF = 3:1 Approx. 80



Changes in Pickup Voltage by CoilTemperature Rise (Hot start)

The coil resistance of a DC-switchingrelay increases (as the coil temperaturerises) when the coil has been continu-ously energized, de-energized once, andthen immediately energized again. Thisincrease in the coil resistance raises thevoltage value at which the relay operates.Additionally, the coil resistance riseswhen the relay is used at a high ambienttemperature.

Upper-Limit Pickup Voltage

The maximum voltage applicable to arelay is determined in accordance withthe coil temperature rise and the coilinsulation materials’ heat resistivity,electrical as well as mechanical servicelife, general characteristics, and otherfactors.

If a voltage exceeding the maximumvoltage is applied to the relay, it maycause the insulation materials todegrade, the coil to be burnt, and therelay to malfunction at normal levels.

• The coil temperature must not exceedthe temperature that the coil canwithstand.

How to calculatecoil temperature

t = R2 - R1/R1 (234.5 = T1) + T1 (°C)

where,R1 (Ω): coil resistance before energizingR2 (Ω): coil resistance after energizingT1 (°C): coil temperature (ambient)before energizingt (°C): coil temperature after energizing

• Before using the relay, confirm that noproblem occurs.

DC Input Power Source

Pay attention to the coil polarity of theDC-switching relay. Power sources forDC-operated relays are usually a batteryor a DC power supply, either with amaximum ripple of 5%. If power issupplied to the relay via a rectifier, thepickup and dropout voltages vary withthe ripple percentage. Therefore, checkthe voltages before actually using therelay. If the ripple component is ex-tremely large, chatter may occur. If thishappens, it is recommended that asmoothing capacitor be inserted asshown below. The use of a regulated,filtered power supply is preferred for DCcoils.

Notes on Coil Input

Coil Information

where,Emax: maximum value of ripple componentEmin: minimum value of ripple componentEmean: mean value of DC component



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Electrical Characteristic Terms

Dielectric strengthThe critical value which a dielectric canwithstand without rupturing when a high-tension voltage is applied for 1 minutebetween the following points:

Between coil and contactBetween contacts of different polesBetween contacts of same polesBetween set coil and reset coilBetween current-carrying metal parts andground terminal

Note that normally a leakage current of3 mA is detected; however, a leakagecurrent of 1 mA or 10 mA may be detectedon occasion.

Electrical service lifeThe life of a relay when it is switched at therated operating frequency with the ratedload applied to its contacts.

Surge suppression voltageThe critical value which the relay canwithstand when the voltage surgesmomentarily due to lightning, switching aninductive load, etc. The surge waveformwhich has a pulse width of ±1.2 x 50 µs isshown below:

Insulation resistanceThe resistance between an electric circuitsuch as the contacts and coil, andgrounded, non-conductive metal partssuch as the core, or the resistancebetween the contacts. The measuredvalues are as follows:

Rated insulation Measuredvoltage value

60 V max. 250 V

61 V min. 500 V

Maximum operating frequencyThe frequency or intervals at which therelay continuously picks up and drops out,satisfying the rated mechanical andelectrical service life.

Mechanical service lifeThe life of a relay when it is switched at therated operating frequency without the ratedload.

Operate bounce timeThe bounce time of the normally open (NO)contact of a relay when the rated coilvoltage is applied to the relay coil at anambient temperature of 23°C.

Operate timeThe time that elapses after power is appliedto a relay coil until the first NO contactshave closed, at an ambient temperature of23°C. Bounce time is not included. For therelays having a pickup time of less than 10ms, the mean (reference) value of its pickuptime is specified as follows:

Pickup time5 ms max. (mean value:approx. 2.3 ms)

Release bounce timeThe bounce time of the normally closed(NC) contact of a relay when the coil is de-energized at an ambient temperature of23°C.

Dropout timeThe time that elapses between the momenta relay coil is de-energized until the NCcontacts have closed, at an ambienttemperature of 23°C. (With a relay havingSPST-NO or DPST-NO contacts, this is thetime that elapses until the NO contactshave operated under the same condition.)Bounce time is not included. For the relayshaving a dropout time of less than 10 ms,the mean (reference) value of its dropouttime is specified as follows:

Dropout 5 ms max. (mean value:time approx. 2.3 ms)

Reset pickup time (applicableto latching relays only)The time that elapses from the moment arelay coil is de-energized until the NCcontacts have closed, at an ambienttemperature of 23°C. (With a relay havingSPST-NO or DPST-NO contacts, this is thetime that elapses until the NO contactshave operated under the same condition.)Bounce time is not included. For the relayshaving a pickup time of less than 10 ms, themean (reference) value of pickup time isspecified as follows:

Reset 5 ms max. (mean value:Pickup time approx. 2.3 ms)

Set pickup timeThe time that elapses after power is appliedto a relay coil until the NO contacts haveclosed, at an ambient temperature of 23°C.Bounce time is not included. For the relayshaving a pickup time of less than 10 ms, themean (reference) value of the pickup time isspecified as follows:

Set 5 ms max. (mean value:Pickup time approx. 2.3 ms)

ShockThe shock resistance of a relay is dividedinto two categories: “Mechanical durability”that quantifies the characteristic change of,or damage to, the relay due to considerablylarge shocks which may develop during thetransportation or mounting of the relay, and“Malfunction durability” that quantifies themalfunction of the relay while it is inoperation.

Stray capacitanceThe capacitance measured betweenterminals at an ambient temperature of23°C and a frequency of 1 kHz.

VSWR (applicable to high-frequencyrelays only)Stands for voltage standing-wave ratio. Thedegree of reflected wave that is generatedin the transmission line.

VibrationThe vibration resistance of a relay is dividedinto two categories: “Mechanical durability”that quantifies the characteristic changes of,or damage to, the relay due to considerablylarge vibrations which may develop duringthe transportation of mounting of the relay,and “Malfunction durability” that quantifiesthe malfunction of the relay due to vibra-tions while it is in operation.

∝ = 0.002f2Awhere,∝: G-force equivalencef: Frequency (Hz)A: Double amplitude (in.)


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Notes on Correct Use

Before actually committing any compo-nent to a mass-production situation,Omron strongly recommends situationaltesting, in as close to actual productionsituations as possible. One reason is toconfirm that the product will still performas expected after surviving the manyhandling and mounting processesinvolved in mass production. AlthoughOmron relays are individually tested anumber of times and each meets strictrequirements, a certain testing toleranceis permissible. When a high-precisionproduct uses many components, eachdepends upon the rated performancethresholds of the other components.Thus, the overall performance tolerancemay accumulate to undesirable levels. Toavoid problems, always conduct testsunder the actual application conditions.

General

To maintain the initial characteristics of arelay, exercise care that it is not droppedor mishandled. For the same reason, donot remove the case of the relay;otherwise, the characteristics maydegrade. Avoid using the relay in anatmosphere containing chemicals suchas sulfuric acid (SO2), hydrogen sulfide(H2S), or other corrosive gases.

Do not continuously apply a voltagehigher than the rated maximum voltageto the relay. Never try to operate the relayon a voltage and a current other thanthose rated.

If the relay is intended for DC operation,the coil has a polarity. Pay particularattention to this polarity. Connect thepower source to the coil in the correctdirection.

Do not use the relay at a temperaturehigher than that specified in the catalogor data sheet.

Coil

AC-switching relaysGenerally, the coil temperature of theAC-switching relay rises higher than thatof the DC-switching version. This isbecause of resistance losses in theshaded coil, eddy-current losses in themagnetic circuit, and hysteresis losses.Moreover, a phenomenon known as“chatter” may take place when the AC-switching relay operates on a voltage

lower than that rated. For example,chatter may occur if the relay’s supplyvoltage drops. This often happens whena motor (which is to be controlled by therelay) is activated. This results in damageto the relay contacts by burning, contactweld, or disconnection of the self-holdingcircuit. Therefore, countermeasures mustbe taken to prevent fluctuation in thesupply voltage.

One other point that requires attention isthe “inrush current.” When the relayoperates, and the armature of the relay isreleased from the magnet, the imped-ance drops. As a result, a current muchhigher than that rated flows through thecoil. This current is known as the inrushcurrent. (When the armature is attractedto the magnet, however, the impedancerises, decreasing the inrush current tothe rated level.) Adequate considerationmust be given to the inrush current,along with the power consumption,especially when connecting severalrelays in parallel.

DC-switching relaysThis type of relay is often used as a so-called “marginal” relay that turns ON orOFF when the voltage or current reachesa critical value, as a substitute for ameter. However, if the relay is used inthis way, its control output may fail tosatisfy the ratings because the currentapplied to the coil gradually increases ordecreases, slowing down the speed atwhich the contacts move.

The coil resistance of the DC-switchingrelay changes by about 0.4% per degreeC change in the ambient temperature. Italso changes when the relay generatesheat. This means that the pickup anddropout voltages may increase as thetemperature rises.

Coil Operating Voltage Source

If the supply voltage fluctuates, this relaywill malfunction regardless of whetherthe fluctuation lasts for a long time oronly for a moment. For example, assumethat a large-capacity solenoid, relay,motor, or heater is connected to thesame power source as the relay, or thatmany relays are used at the same time. Ifthe capacity of the power source isinsufficient to operate these devices atthe same time, the relay may not

operate, because the supply voltage hasdropped. Conversely, if a high voltage isapplied to the relay (even after takingvoltage drop into account), chances arethat the full voltage will be applied to therelay. As a consequence, the relay coilwill generate heat. Therefore, be sure1) to use a power source with sufficientcapacity and 2) that the supply voltage tothe relay is within the rated pickupvoltage range of the relay.

Lower Limit Pickup Voltage

When a relay is used at high tempera-tures, or when the relay coil is continu-ously energized, the coil temperaturerises and coil resistance increases.Consequently, the pickup voltageincreases. This increase in the pickupvoltage requires attention when deter-mining the lower-limit pickup value of thepickup voltage. An example and outlinefor determining this lower-limit pickupvoltage is given below for reference whendesigning a power source appropriate forthe relay.

Assuming a coil temperature rise of10°C, the coil resistance will increaseabout 4%. The pickup voltage increasesas follows:

Rated values of Model G5LE are takenfrom catalog or data sheet.Rated voltage: 12 VDCCoil resistance: 360 ΩPickup voltage: 75% max. of ratedvoltage at 23°C coil temperature

The rated current that flows through thisrelay can be obtained by dividing therated voltage by the coil resistance.Hence,

12 VDC ÷ 360 Ω = 33.3 mA

However, the relay operates at 75%maximum of this rated current, i.e.,25 mA (= 33 mA x .75). Assuming thatthe coil temperature rises by 10°C, thecoil resistance increases 4% to 374 Ω(= 360 Ω x 1.04). The voltage that mustbe applied to the relay to flow anoperating current of 25 mA through therelay under this condition is 25 mA x374 Ω = 9.35 V.



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Ambient Temperature vs. Pickup/Dropout Voltage (Model G6S)

As can be seen in the above chart,pickup and dropout voltage are affectedby changes in ambient temperature.These changes should be taken intoaccount if the relay will operate outsideof a controlled environment.


-60 -40 -20 0 20 40 60 80 100

100

90

80

70

60

50

40

30

20

10

0

Max. estimated value

Ambient temperature (°C)

Per

cent

age

agai

nst

r ate

d vo

ltage

(%

)

Classification by Degreeof Protection

Relays are divided by classification of thedegree of protection.

ConstructionUnsealedThis type of relay cannot be immersion-cleaned.

Semi-sealed typeSpecial design construction prevents fluxfrom penetrating into the relay basehousing, for example, due to capillaryaction up the terminals when the relay issoldered onto a PCB. This type of relaycannot be immersion-cleaned.

Fully sealed typeThese relays are sealed in a thermoplas-tic case or cover as protection against anatmosphere containing corrosive gases.

The plastic sealed relay is of simpleconstruction in which the relay is placedin a plastic case. The gaps of the jointsbetween the case and relay terminals,and between terminals and terminalblock (base) are sealed with epoxy resin.

Fully sealed relays are protected fromflux and any cleaning solvent frompenetrating into the relay housing. Thistype of relay can be immersion-cleaned.Relays are tested in flourinert at 90°C for1 minute before being shipped.

Due to its simple construction, the plasticsealed relay is not suitable for applica-tions in an environment or installationlocation that requires a particularly highlevel of sealing. For applications in anatmosphere containing flammable orexplosive gases, use an hermeticallysealed relay.

The following points require yourparticular attention to effectively preventnoxious gases or liquids from penetratinginside the relay.

1. There is no problem as long as therelay is used on a flat surface.However, as much as possible, use itin an atmosphere pressure of1,013 mb ±20%.

2. Do not use clean flux or water wash.

Operating atmosphereUse of the plastic sealed or hermeticallysealed relay is recommended under thefollowing conditions:

When the relay is soldered on a PCboard to be immersion-cleaned.

In an atmosphere containing organicgases such as ammonia or hydrogensulfide, SO2 and chloride gas.

On the control panel for machinetools that produce dust and oil.

In terminal equipment installed at alocation where people move about tocreate a dusty atmosphere.

In automatic vending machines andshowcases installed outdoors.

Pickupvoltage

Max.

Avg.

Min.

DropoutvoltageMax.Avg.Min.


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AutomaticAutomatic Automatic Manual Protection

ProtectionClassification Construction Features flux

soldering cleaning soldering from dustfrom corrosive

application gas

Poor Poor Poor Good

Unsealed type Fair Poor

Poor Poor Poor Good

Good Good Poor Good

Semi-sealed type Fair Poor

Good Good Poor Good

Fully-sealed Good Good Good Good Good Fairtype

Terminals areseparated fromPCB surface whenrelay is mounted.

Contacts arepositioned awayfrom base.

Terminals arepressed into base.

Terminals areinserted into base0.3 mm or morethick.

Terminals, base,and case aresealed.

Terminals separatedfrom PCB

Contacts located atupper part of relay case

Press-fit terminals

Terminals Resin sealseparatedfrom PCB

Inserted terminals

Terminalsseparatedfrom PCB

0.3 mm min.base thickness

Press-fit terminals

Resin seal

Relay Driving Signal Waveform

A long rise time and/or fall time of thesignal driving the relay may prolong thepickup time and/or dropout time of therelay. This situation may shorten the lifeexpectancy of the contacts. If thissituation cannot be avoided, providing aSchmitt trigger circuit at the circuit stagepreceding the relay circuit will shape awaveform with sharp transitions, asshown:

NOTE: If the Schmitt trigger circuit isconfigured of transistors, aresidual voltage may exist in theoutput of the circuit. Therefore,confirm that the rated voltage ispresent across the relay coil, orthat the residual voltage drops tozero when the relay releases.

Cyclic Switching of AC Load

If the relay operates in synchronizationwith the supply voltage, the life of therelay may be shortened. When designingthe control system in which the relay isused, estimate the life expectancy of therelay and thus the reliability of the overallsystem under the actual operatingcondition. Moreover, make an arrange-ment so that the relay operates in arandom phase or in the vicinity of thezero point.



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Temperature and humidityPCBs expand or contract with changes intemperature. Should expansion occurwith a relay mounted on the PCB, theinternal components of the relay may beshifted out of operational tolerance. As aresult, the relay may not be able tooperate with its normal characteristics.

PCB materials have “directionality”,which means that a PCB generally hasexpansion and contraction coefficients1/10 to 1/2 higher in the verticaldirection than in the horizontal direction.Conversely, then, it follows that its warpin the vertical direction is 1/10 to 1/2 lessthan in the horizontal direction. There-fore, take the adequate countermeasuresagainst humidity by coating the PCB.

Should heat or humidity be too high, therelay’s physical characteristics will beaffected. For example, as the heat risesthe PCB’s insulation resistance de-grades. Mechanically, PCB parts willcontinue to expand as heat is applied,eventually passing the elastic limit, whichwill permanently warp components. If therelay is used in a humid environment,silver migration may take place.

GasExposure to gases containing sub-stances such as sulfuric acid, nitric acid,or ammonia can cause malfunctionssuch as faulty contacting in unsealedrelays. They can also cause the copperfilm of a PCB to corrode, or preventpositive contacts between the PCB’sconnectors. Of the gases mentioned, gascontaining nitric acid is particularlydamaging as it tends to accelerate thesilver migration. As a countermeasureagainst gas exposure damage, thefollowing processes on the relay andPCB have proved useful:

Item Process

Outer casing, Sealed construction byhousing using packing, etc.

Relay Use of simplifiedhermetically sealedtype relay, DIP relay.

PCB, copper Coatingfilm

Connector Gold-plating, rhodium-plating process

PC Board Design


Vibration and shockAlthough the PCB itself is not usually asource of vibration or shock, it maysimplify or prolong the vibration bysympathetically vibrating with externalvibrations or shocks. Securely fix thePCB, paying attention to the followingpoints:

Mounting Remarksmethod

Rack No gap between rack’smounting guide and PCB

Screw Securely tighten screw.mounting Place heavy components such

as relays on part of PCB nearscrews.

Attach rubber washers toscrews when mountingcomponents that are affectedby shock noise (such as audio

devices).

Mounting Relay on PC Board

Mounting directionTo allow a relay to operate to its fullcapability, adequate consideration mustbe given to the mounting direction of therelay. Relay characteristics that areconsiderably influenced by mountingdirection are shock resistivity, lifeexpectancy, and contract reliability.

Shock resistivityIdeally, the relay must be mounted sothat any shock or vibration is applied tothe relay at right angles to the operatingdirection of the armature of the relay.Especially when a relay’s coil is notenergized, the shock resistivity and noiseimmunity are significantly affected by themounting direction of the relay.

Life expectancyWhen switching a heavy load thatgenerates arc (generally, a load having agreater impedance than that of the relaycoil), substances spattered from thecontact may accumulate in the vicinity,resulting in degradation of the insulationresistance of the circuit. Mounting therelay in the correct direction is alsoimportant in preventing this kind ofdegradation of the insulation resistance.

Contact reliabilitySwitching both a heavy and a minuteload with a single relay contact is notrecommended. The reason for this is thatthe substances scattered from thecontact when the heavy load is switcheddegrade the contact when switching theminute load. For example, when using amulti-pole contact relay, avoid themounting direction or terminal connec-tions in which the minute load switchingcontact is located below the heavy loadswitching contact.

Mounting intervalWhen mounting multiple relays side byside on a PCB, pay attention to thefollowing points:

When multiple relays are mountedside by side, they may generateabnormally high heat due to thethermal interference between therelays. Provide an adequate distancebetween the relays to dissipate theheat. When using a relay, be sure tocheck the minimum mounting intervalof the relay.

If the multiple PCBs are mounted to arack, the temperature may rise. In thiscase, preventive measures must betaken so that the ambient temperaturefalls within the rated value.


12

Conformal coatingCoating the PCB is recommended toprevent the circuitry from being degradedby harmful gases. When coating thePCB, care should be taken to avoid relaycontamination. Otherwise, faulty contactof the relay may occur due to sticking orcoating. Some coating agents maydegrade or adversely affect the relay.Select the coating agent carefully.

Type of coating

Applicabilityto PCB with Featurerelay mounted

Epoxy Good Good insulation.Applying this coating is alittle difficult, but has noeffect on relay contact.

Urethane Good Good insulation and easyto coat. Be careful not toallow the coating on therelay itself, as thinner-based solvents are oftenused with this coating.

Silicon Poor* Good insulation andeasy to coat. However,silicon gas may causecontact contaminationand mis-operation.

* Satisfactory for sealed, but totally unsatisfactoryfor unsealed relays.

Driving by Transistor

When a transistor is used to drive therelay, be sure to ground the emitter of thetransistor.

When the transistor is used in emitter-follower configuration (i.e., the collector isgrounded), give adequate considerationto the voltage across the collector andemitter. The required voltage must beapplied to the relay.

NPN transistor

PNP transistor


Advice on selecting a transistorfor driving the relay1. From the relay catalog or data sheet,

ascertain the following coil character-istics:Rated voltage ________ VDCRated current ________ mACoil resistance _______ Ω

2. Determine the lower- and upper-limitvalues of the pickup voltage from therated voltage.Lower-limit pickup voltage _____VUpper-limit pickup voltage _____V(If surge is contained in the ratedvoltage, obtain the maximum valueincluding the surge.)

3. By determining the component forsuppressing surge, obtain thedielectric strength of the transistor fordriving the relay.<In the case of diode>(Upper-limit of pickup voltage + 0.6)x 2* =~ VCEO =~ VCBO = ___V<In the case of diode and zenerdiode>(Upper-limit of pickup voltage + 0.6 +breakdown voltage**)x 2* =~ VCEO =~ VCBO = ___V<In the case of varistor>(Upper-limit pickup voltage + varistorvoltage***) x 2* =~ VCEO =~ VCBO = ___V<In the case of RC>(Upper-limit pickup voltage + surgevoltage****) x 2* =~ VCEO =~ VCBO = ___V

4. Determine collector current lc.lc = Upper-limit pickup voltage/Coilresistance x 2*

5. Select the transistor that satisfies theconditions determined in steps 3 and 4.

6. After selecting the transistor, observethe lC vs. VCE characteristics of thetransistor indicated in its ratings.

The characteristic curve illustrates therelation between collector current lC

and collector-emitter voltage VCE atbase current lB. From this graph,obtain collector-emitter voltage VCE

where,

lC = Maximum value of must operatevoltage/Coil resistance

lB = Base current of the switchingtransistor which is determined by thedriver stage.

Thus, Collector-emitter voltageVCE = V

Use the transistor in its switching(saturation) area. An adequate basecurrent is required.

* This safety factor must be determined by theuser.

** The breakdown voltage differs depending onthe component. If multiple zener diodes are tobe used, use their maximum breakdownvoltage.

*** The varistor voltage differs depending on thecomponent. In addition, the varistor voltage ofa single varistor may vary depending on thecurrent. Consult the manufacturer of thevaristor to be used to determine the varistorvoltage.

**** The surge voltage differs depending on thetype and rating of the relay, and tde`constantsof C and R of the circuit in which the relay isused. Positively determine the surge voltageby experiment.

IC vs. VCE characteristics



13


7. Using the following formula, calculatethe power dissipated by the transistorto confirm that it is within the range ofpermissible power dissipation of thetransistor.

Total power dissipation PT = Collectordissipation PC + Base dissipation PB

where,

PC= Maximum value of pickup voltage/Coil resistance x VCE

(VCE is determined in step 6.)PB = lB x 0.6 to 1(For details on lB, refer to step 6.)

Confirm that PT obtained by the aboveformula is within the curve represent-ing the total power dissipation vs.ambient temperature characteristics.

Total power dissipation vs.ambient temperature

In case the total dissipation exceeds thepermissible power dissipation, eitherattach a radiator plate to the transistor, orreplace the transistor.

8. Determine the supply voltage to therelay.

The maximum and minimum valuesof the supply voltage to the relay aredetermined by the following expres-sions using the upper- and lower-limitvalues of he pickup voltage VCE

obtained in step 6.

Maximum supply voltage = Upper-limit pickup voltage + VCE

Minimum supply voltage = Lower-limit pickup voltage + VCE

9. Verify that the following conditionsare satisfied.

VCEO > (Maximum supply voltage +surge voltage) x safety factor*

VCBO > (Maximum supply voltage +surge voltage) x safety factor*

* Determine the safety factor giving consider-ation to external surge (such as lightning andsurge from other devices).

10. Check the following items duringactual use of the relay.

Is the upper-limit value of thepickup voltage equal to or lessthan the rated value when themaximum supply voltage isapplied?

Is the lower-limit value of thepickup voltage equal to or morethan the rated value when theminimum supply voltage isapplied?

Are the above conditions satisfiedwithin the operating temperaturerange?

Is there any abnormality found in atest run?

In addition to checking the aboveitems, take into consideration theitems listed in this table.

Rated voltage of relay Low High

Coil current* High Low

IC of switching transistor High Low

VECO

, VCEO

of switching Low Hightransitistor**

Driving current of transistor High Low

Voltage drop VCE in transistor High Low

Total power dissipation High LowP

T of transistor

* Inversely proportional to voltage** Often used V

CEO: 35 to 60 V

From the above discussion, the bestrelay coil should be rated at 12 VDC or24 VDC when the relay is driven by atransistor.

Driving by Darlington-ConnectedTransistors

To reduce the current of the transistor todrive the relay (i.e., base current of thetransistor), two transistors may be used,via Darlington connection. Darlington-connected transistors are availableenclosed in a single package.

NPN-NPN Darlington Connection

When the Darlington-connected transis-tors are used, the required value of VCE ishigher than when using a single transis-tor. For this reason, consideration mustbe given to designing the total powerdissipation and supply voltage for thesecond transistor, Tr2.

Driving by IC

Recently, an IC on which multiple drivingtransistors are integrated has becomeavailable. The designing of the circuit orPCB to drive multiple relays, a small-sizesolenoid, or a small-size lamp can besimplified by using this IC. Consult themanufacturer of the IC for details. ForVCE, refer to the description of the relatedvoltage and surge suppressor.

Dimensions Connection (Top view)

Equivalent circuit

I: Input (Base)O: Output (Collector)GND (Common Emitter)


14


Driving by TTL

TTLs can be divided into two types byclassification of the output: totem-poleand open-collector outputs. Connectionof each type of TTL is described below.

Use a diode as surge suppressor.

In the specifications of some ICs, such aphrase as “fan-out 10” may be used inplace of the legend IOL. This denotes that10 standard TTLs can be connected inparallel. In terms of current, fan-out 1equals 1.6 mA. Hence,Fan-out n = 1.6 x n (mA)

1. To drive a relay by the totem-poleoutput of a TTL, these conditionsmust be satisfied:

IOL (low-level output current) >Maximum supply voltage/Coilresistance.

IOH (high-level output current) <Rated current x pickup voltage(%)/Coil resistance

Minimum supply voltage (4.75 V) -Maximum VOL (low-level outputvoltage) > Lower-limit value ofpickup voltage (Refer to Driving byTransistor)

Totem-pole output

2. To drive a relay with open-collectoroutput type TTL, a degree of freedomis allowed in the ratings of the relaycoil. However, these, conditions mustbe satisfied:

IOL > Maximum supply voltage tothe relay coil/Coil resistance

IOH < Rated current x pickupvoltage (%)/200

VO = Dielectric strength of the out-put transistor (Refer to Driving byTransistor.)

VOL = Collector emitter voltage VCE

of the output transistor (Refer toDriving by Transistor.)

Open-collector output

The above description of the standardTTL is applicable when using S, H, andLS type TTLs.

Driving by Other Switching Devices

Consult the manufacturer of the switchingdevice. The upper- and lower-limit valuesof the pickup voltage can be determinedin the same manner as described inUpper-limit Pickup Voltage and Lower-limit Pickup Voltage.

Example of Driving by SCR

Designing Power Circuit

Since many documents and referencebooks on the power circuit are available, adetailed description is omitted here.

* In the circuit above, varistors B1 and B

2 are

used to protect the power circuit elements, aswell as elements related to the power circuit, incase the voltage on the power line experiencessurges (due to lightning or the surge voltagegenerated in other devices connected to thepower circuit). Connect an appropriate surgesuppressor across the output terminals of thepower circuit to prevent a surge voltage frombeing generated. The surge suppressor mustkeep the surge voltage, if generated, fromexceeding the breakdown voltage of eachelement in the power circuit.

** Resistor R protects diode bridge D from theinrush current that flows through the powercircuit upon power application. Although theresistance of R is determined according to theresistance of the load coil and the ratings ofthe diodes, the use of a resistor having aresistance of 0.1 to 100 Ω is recommended.

*** C1 is a smoothing capacitor. Its capacitance

must be as large as possible to reduce thesurge percentage.

Connection of Surge Suppressor

NOTE:This graph is plotted by measuring thesurge voltage in the line of low-tensionoverhead wiring (cable length: 200 to500 m).

When connecting a surge suppressor,pay attention to the following points:

1. Place the surge suppressor near thedevice to be protected. For example,to protect a device from externalsurge, set the surge suppressor at theinlet of the device’s power cable.

To suppress an internal surge, thesuppressor must be placed near thesurge generating source.

External surge

Internal surge

2. The cable for connecting the surgesuppressor must be as short aspossible in length, and thick enoughin diameter so that it can sufficientlywithstand the surge current. The shortlength and thick diameter areimportant to reduce the inductanceand generated voltage, and to protectthe device from heat damage.



15

3. When using a surge suppressorbetween cable and ground, the lowerthe ground resistance of the surgesuppressor, the better the protectiveeffect of the surge suppressor.Perform grounding at a groundresistance of 10 Ω or less.


Countermeasures Against Supply Voltage Fluctuation

In case the supply voltage fluctuates heavily, insert a regulated voltage circuitor constant-voltage circuit in the application circuit as shown below.

Relays consume more power than semiconductor elements. The followingcircuit configuration is recommended to improve the characteristics.

Countermeasures Against Inrush Current

If a load such as a capacitor or lamp through which an inrush current flows isconnected to the power source and contact of the relay, the supply voltage maydrop when the contact is closed, causing the relay to abnormally release.

Increasing the capacity of the transformer or providing an additional controlcircuit can be used to prevent this drop in the supply voltage. On some occa-sions, use of the following circuit may prevent voltage drop.

The same circuit also applies when therelay is driven by a battery.


16


This section introduces a patented drivecircuit for the single-winding latchingrelay that can be driven on severalmilliwatts. This drive circuit not onlyallows the relay to be used in the samemanner as semiconductor devices butalso offers a wide range of applications.

Operating principle

SetWhen a specified voltage is appliedacross E, the current flows through thecircuit in the sequence of diode Di1,capacitor C, relay Ry, and diode Di2.C is then charged, setting the relay.

EnergizationWhen C has been fully charged, the relayis biased by the current flowing from Di1to Rb. C does not discharge. The powerconsumption at this time is very small,several milliwatts at best, and its valuecan be calculated as follows:

P = (E–VF)2/Rb

where,P: power consumptionVF: voltage drop across diode Di1

The current that is to flow through Rb atthis time is dependent on the transferratio hfe of transistor TR which isrequired for TR to turn ON.

ResetWhen the voltage placed across E isremoved, the electricity charged in C isdischarged, causing the current to flowthrough the circuit in the sequence of Rb,the base, and the emitter of TR. In thisway, the relay is reset by the currentflowing in the direction opposite to whenthe relay is set.

The following equivalent circuits respec-tively illustrate the current flows when therelay is set, energized, and reset.

Designing Power-Conserving Driver Circuit with Single-Winding Latching Relay (Pat. 1239293)

Set

Energization

Reset



17


Circuit designFundamentalGenerally, the latching relay is set andreset when a pulse having a squarewaveform is applied to it for a short time.The minimum pulse width required to setand reset the relay is predetermined.

The charging current shown in the aboveequivalent circuit diagrams, has asawtooth waveform that can be expressedby the following formula, because it is theprimary circuit of C and R.

i = E-2VF/R ∈ - 1/CRt

(2 Forward voltage diode drops)

If applied voltage E and the rated coilvoltage of the relay are the same, thecurrent to the relay falls short by thequantity indicated by the shaded portionin the following figure.

Therefore, the current must be applied tothe relay as follows when designing thisdriver circuit.

Time constantWhen the rated voltage is applied to therelay, time A in the timing chart below isrequired to turn ON the contacts. Afterthis time has elapsed, time B is requireduntil the armature attraction to themagnet is complete.

Therefore, it is apparent that timeconstant T obtained as the product of Cand R must be equal to or longer thanthe sum of A and B. Actually, however, Tshould not be equal to the sum of A andB but must be longer than that to ensurethe stable operation of the circuit. Thus,

T = A + B + X

where X is the time margin.

The set time A of OMRON’s moving-looprelays (with a pickup power of 200 mW)is rated at about 3 milliseconds. Timeconstant T for them should be aboutthree times that of A. The following graphillustrates this. This graph indicates that,if C is completely charged (IPEAK), it takes4.6T to discharge I to 1%. Note that timeconstant T is broken down into threesegments. The first 1/3T equals A, thesecond 1/3T, B. The remaining 1/3T isthe time margin expressed as X in theabove equation. T is three times A.

Voltage drop E1 across the totalresistance of the capacitance C’sresistance and relay coil’s internalresistance is the difference between thesupply voltage E and voltage dropsacross two diodes:Di1 and Di2. Hence,

E1 = E – 2VF

Assuming the supply voltage to be 5 Vand VF to be 0.6 V,

E1 = 5 – 2 x 0.6 = 3.8 V

From E1 and the above graph, therequired coil voltage of a relay can beobtained. Again assuming the E, i.e., thesupply voltage of a single-windinglatching relay is 5 V, the coil voltage is:

3.8 x 0.72 = 2.7 V

At this time, the capacitance of C is246.9 µF, according to the equationshown in the above graph.


18


Coil ratings and capacitance of CIn the example, the coil voltage obtainedby calculation is 2.7 V, which is 0.3 V lessthan the value at which the coil voltage ofcommercially available standard latchingrelay is rated. The standard coil voltagesof relays at a supply voltage of 6, 9, 12,and 24 V can be respectively calculatedin the same way. Table 1 compares theresults of the calculation and the coilvoltages of standard relays.

The calculated coil voltages significantlydeviates from the standard values. It istherefore necessary to determine thetime constant of the relay by adjustingthe capacitance of C when the relay coilis to operate on the standard voltage.

As an example, calculate the capaci-tance of C and time constant T of a relaywith a rated supply voltage of 5 V. Thecoil voltage E1 has been calculatedabove (3.8 V). To determine how muchcurrent I flows through the coil at 3.8 V,from Table 1, note that the coil resistanceis 45 Ω. So,

I = 3.8/45 = 84.4 mA

Therefore, the peak current of capacitorC to be used must be 84.4 mA.

Remember, that time A of an OMRONrelay is 3 ms. Capacitance C must be avalue that allows 66.6 mA to flow through3 ms after 5 V is applied to the relay.Thus,

66.6 = 84.4∈ 1/cx45 3x10–3

From this,

C = 280 µF

At this time, time constant T is:

280 x 10–6 x 45 = 12.6 ms

By calculating the C of each of the relayslisted in Table 1, the values in Table 2 areobtained.

Again, these calculated capacitancesdeviate from the commercially availablestandard capacitors. There is no problemin using standard capacitors but, if thecost and circuit space permit, it isrecommended to use two or morecapacitors so that a capacitance as closeto the calculated value as possible isobtained. At this time, pay attention tothe following points:

Confirm that the relay operatesnormally even when the supplyvoltage is brought to 80%-120% of therated value.

Even if a voltage of two or three timesthe rated voltage is applied to thisdriver circuit, the coil wire will notsever. That is why, for example, whenthe driver circuit is mounted in anautomobile where a supply voltage of12 VDC is available from the battery, itis recommended to use a relay whosecoil voltage is rated at 6 VDC, taking avoltage fluctuation of 8 to 16 VDC intoconsideration.

Determining RbThe current flows into Rb should beenough to turn ON TR when the relay isreset. When determining value of Rb, thefollowing points must be noted:

TR must be sufficiently turned ONeven when T equals the time constant.

Give adequate consideration tochanges in hfe due to changes inambient temperature.

Simple as it is, the driver circuit intro-duced here can efficiently control therelay, consuming a tiny amount of power.

An experiment reveals that the relaysufficiently operates with a capacitanceof 100 µF + 47 µF where the relay israted at a supply voltage of 5 VDC and acoil voltage of 3 VDC. It can therefore besaid that the capacitance can be lowerthan the calculated value. This isbecause the time constant is determinedwith a relatively wide margin. So it isrecommended to perform experiments todetermine the time constant.

Application circuit example

The TTL output of a solid-state switchcan be used as Q2.

Half-wave rectified AC power is appliedto the circuit. Q1 is the output of a TTL,and drives the relay.

Table 1

Supply voltage Coil voltage (calculated) Standard voltage Coil resistance

5 V 2.7 V 3 V 45 Ω

6 V 3.5 V 3 V 45 Ω

9 V 5.6 V 5 V 125 Ω

12 V 7.8 V 6 V 405 Ω

24 V 16.4 V 12 V 720 Ω

Table 2

Supply voltage Coil voltage (calculated) Coil resistance Capacitance of C

5 V 2.7 V 45 Ω 280 µF

6 V 3.5 V 45 Ω 142 µF

9 V 5.6 V 125 Ω 54 µF

12 V 7.8 V 405 Ω 40 µF

24 V 16.4 V 720 Ω 6.5 µF



19

Mounting Relay on PCB

Manual soldering is the best way to mount the relay onto a PCB. However, dependingon the construction of the relay, dip or automatic soldering can be performed. Thefollowing tables list the processes required for mounting the relay onto a PCB and thepoints to be noted in each process.

Manual soldering Automatic soldering

1. Connectionandmounting

2. Fluxapplication

3. Preheating

4. Soldering

To connect a lead wire to the terminal or to mount the relay ona PC board, securely wind the lead wire around the terminalas shown.

Use an anticorrosive rosin-type flux or water washableorganic fluxes with consideration given to the applicability ofthe flux to the relay’s components.

For flux solvent, use alcohol type, which is less chemicallyreactive.

Apply flux sparingly and evenly to prevent penetration ofsolder flux into the relay. When dipping the relay terminals intosolder flux, be sure to adjust the position of the flux level, sothat the upper surface of the PC board is not flooded with flux.

_____

Complete soldering quickly and firmly with a soldering ironwhile smoothing the applied solder with the tip of the solder-ing iron.

Soldering iron: rated at 30 to 60 W Tip temperature: 280 to 300°C Soldering time: 3 sec. max. The following is an example of the solders recommended

for use in hand soldering.

The solder shown above is provided with a cut section toprevent flux from being scattered.

Type Sparkle solder V

Applicable solder diameter 0.03 to 0.06 in.

Sn 58.8%

Flux content 1.67%

Impurities JIS Z 3282 Class A

Spread rate 90%

Storage 3 months max.

Process the land part of theprinted circuit board asillustrated on the right toprevent the terminal holeof the relay from beingfilled with solder, and toimprove the reliability ofthe solder connection.

Preheat the PC boardto dry the applied fluxat a temperature of100°C max.

Flow soldering is recommended to assureuniform quality of soldering.

Solder temperature and soldering time:260°C… 3 sec. max.

Adjust the position of the solder level sothat the PC board is not flooded withsolder.


20

Mounting Relay on PCB

Manual soldering Automatic soldering

5. Cooling

6. Generalcleaningprocedures

Avoid cleaning the solder terminals whenever possible. If cleaning cannot be avoided, exercise care in selectingan appropriate cleaning solvent. Some types of relays employ molding materials resistant to chemicals, andcan be cleaned with chlorine or fluorine-based solvents. Direct solvent to only the soldered areas, in order toprevent the possibility of flux-contaminated solvent entering the relay.

Recommended cleaning solvents: Alcohol-based solvents.

List of cleaning methods

Solvent Unsealed Semi-sealed Fully-sealed

PerochleneChloride-based Trichloroethane No • Yes

Trichloroethylene

Water-based Indusco

No No Yes Holys

Alcohol-based IPA

No • Yes Ethanol

Cleaning methodCleaning is not Automatic Automaticrecommended cleaning cleaning

NOTE: 1. Contact Omron representative for recommended cleaning procedures of specific relays.2. • Consult Factory.

Upon completion of theautomatic soldering,forcibly cool the PC boardwith a fan, etc., so that therelay and other compo-nents on the PC board willnot deteriorate from theinertial heat of soldering.



21

Latching Relays

Notes on Drive Circuit

Double-winding type (MY, MK) When a DC-switching latching relay is

used in one of the circuits shown atthe right, the relay contacts may bereleased from the locked state unlessa diode (enclosed in the dotted box inthe circuit diagram) is connected to thecircuit.

When connecting a diode to the relaycircuit, be sure to use a diode with arepetitive peak-inverse voltage, and aDC reverse voltage sufficient towithstand external noise or surge.Determine also that the diode has anaverage rectified current greater thanthe coil current.

If the contact of the relay is used to de-energize the relay, the relay may notoperate normally. Avoid using the relayin a circuit as shown:

Avoid use in locations subject toexcessive magnetic particles or dust.

Avoid use in a magnetic field (over8,000 A/m)

Give thought to preventing problemscaused by vibration or shock. Considerthat these problems may originatefrom other relay(s) operating orreleasing on the same panel.

Notes on Circuit

Circuit connecting two reset coils inparallel

Circuit connecting two set coils in parallel

Circuit connecting set coil to reset coil

Circuit connecting set coil of latchingrelay in parallel with another relay coil

Hints on Correct Use

Avoid simultaneous energization of theset and reset coils, even though bothcoils can be continuously energized.

Avoid use under conditions whereexcessive surge-generating sourcesexist in the coil power source.

When planning to mount multiplerelays side-by-side, observe theminimum mounting interval of eachtype of the relay.

22

• Do not apply excessive voltage orcurrent to the SSR input or outputcircuits, or SSR malfunction or firedamage may result.

• Do not operate if the screws on theoutput terminal are loose, or heatgenerated by a terminal error mayresult in fire damage.

• Do not obstruct the air flow to theSSR or heat sink, or heat gener-ated from an SSR error may causethe output element to short, orcause fire damage.

• Be sure to conduct wiring with thepower supply turned OFF, orelectric shock may result.

Output (load voltage)

Input ONOFF

WARNING

Do not touch the SSR terminal sec-tion (charged section) when thepower supply is ON. For SSRs withterminal covers, be sure to attachthe cover before use. Touching thecharged section may cause electricshock.

Do not touch the SSR or the heatsink either while the power supplyis ON, or immediately after thepower is turned OFF. The SSR/heat sink will be hot and will causeburns.

Do not touch the SSR LOAD termi-nal immediately after the power isturned OFF. The internal snubbercircuit is charged and may causeelectric shock.

!

The mean time to failure (MTTF) ofSSRs is 100,000 hours, which varieswith the operating conditions. To en-sure long life and stable operation,take proper countermeasures againstextremely high or low operating tem-perature, heavy fluctuations of ambi-ent temperature, and/or long continu-ous energization.

1. Unexpected events may occurbefore the SSR is used. For thisreason it is important to test theSSR in all possible environments.For example, the features of theSSR will vary according to theproduct being used.

2. All rated performance values listedin this catalog, unless otherwisestated, are all under the JIS C5442standard test environment (15° to30°C, 25% to 85% relative humidity,and 86 to 106 kPa atmosphere).When checking these values on theactual devices, it is important toensure that not only the loadconditions, but also the operatingenvironmental conditions areadhered to.

!"#

$

$

SSRs need only a small amount ofpower to operate. This is why the in-put terminals must shut out electricalnoise as much as possible. Noise ap-plied to the input terminals may resultin malfunction. The following describemeasures to be taken against pulsenoise and inductive noise.

1. Pulse Noise

A combination of capacitor and resis-tor can absorb pulse noise effectively.The following is an example of a noiseabsorption circuit with capacitor C andresistor R connected to an SSR incor-porating a photocoupler.

Pulse width

Pulse voltage

R

C

• When installing the SSR directly intoa control panel so that the panel canbe used as a heat sink, use a panelmaterial with low thermal resistancesuch as aluminum or steel. If amaterial with high thermal resistancesuch as wood is used, heatgenerated by the SSR may causefire or burning.

An SSR with a zero cross functionoperates when the AC load voltageapproaches the zero point or its vi-cinity and releases when the currentreaches the zero point. An SSR witha zero cross function reduces click-ing noises that may be generatedwhen the load is turned ON.

• Follow the Correct Use section whenconducting wiring and soldering. Ifthe product is used before wiring orsoldering are complete, heatgenerated from a power supply errormay cause fire damage.

The value of R and C must be de-cided carefully. The value of R mustnot be too large, or the supply volt-age (E) will not be able to satisfy therequired input voltage value.

The larger the value of C is, the long-er the release time will be, due to thetime required for C to discharge elec-tricity.

23

Pulse voltage (V)

Pul

se w

idth

( s

)µ

Note: For low-voltage models, suffi-cient voltage may not be ap-plied to the SSR because ofthe relationship between C, R,and the internal impedance.When deciding on a value forR, check the input impedancefor the SSR.

2. Inductive Noise

Do not wire power lines alongside theinput lines. Inductive noise may causethe SSR to malfunction. If inductivenoise is imposed on the input terminalsof the SSR, use the following cablesaccording to the type of inductivenoise, and reduce the noise level toless than the reset voltage of the SSR.

Twisted-pair wire: For electromagneticnoise

Shielded cable: For static noise

A filter consisting of a combination ofcapacitor and resistor will effectivelyreduce noise generated from high-fre-quency equipment.

Filter

Load

High frequencydevice

Note: R: 20 to 100 ΩC: 0.01 to 1 µF

$

1. Input Voltage Ripples

When there is a ripple in the inputvoltage, set so that the peak voltageis lower than the maximum operatingvoltage and the root voltage is abovethe minimum operating voltage.

Peak voltage

Root voltage

0 V

2. Countermeasures for LeakageCurrent

When the SSR is powered by transis-tor output, the reset voltage may beinsufficient due to leakage current dur-ing power OFF. To counteract this,connect bleeder resistance (as shownin the diagram below) and set thebleeder resistance so that VR is 0.5 Vor less.

Bleeder resistance

3. ON/OFF Frequency

The ON/OFF frequency should be setto 10 Hz maximum for AC load ON/OFF and 100 Hz maximum for DCload ON/OFF. If ON/OFF occurs atfrequencies exceeding these values,SSR output will not be able to follow-up.

4. Input Impedance

In SSRs which have wide input volt-ages (such as G3F and G3H), the in-put impedance varies according tothe input voltage and changes in theinput current. For semiconductor-driven SSRs, changes in voltage cancause malfunction of the semicon-ductor, so be sure to check the actualdevice before usage. See the follow-ing examples.

Applicable Input Impedance for a Pho-tocoupler-type SSR without Indicators(Example)G3F, G3H (Without Indicators)

Inpu

t cur

rent

(m

A)

Inpu

t im

peda

nce

(k

)

Input voltage (V)

Ω

Input current

Input impedance

Applicable Input Impedance for a Pho-tocoupler-type SSR with Indicators(Example)G3B, G3F, G3H (With Indicators)

Inpu

t cur

rent

(m

A)

Input voltage (V)

Inpu

t im

peda

nce

(k

)Ω

Input current

Input impedance

Applicable Input Impedance (Example)G3CN

Input voltage (V)

Inpu

t cur

rent

(m

A)

Inpu

t im

peda

nce

(k

)Ω

Input impedance

Input current

24

%

&%'%"

If there is a large voltage surge in theAC current being used by the SSR, theC/R snubber circuit built into the SSRbetween the SSR load terminals willnot be sufficient to suppress the surge,and the SSR transient peak elementvoltage will be exceeded, causingovervoltage damage to the SSR.

Only the following models don’t havea built-in surge absorbing varistor:G3NA, G3S, G3PA, G3NE, G3JC,G3NH, G9H, G3DZ (in part), G3RZ,and G3FM. When switching the in-ductive load ON and OFF, be sure totake countermeasures against surge,such as adding a surge absorbingelement.

In the following example, a surge volt-age absorbing element is added.

Varistor

Load

Varistor

Select an element which meets theconditions in the table below as thesurge absorbing element.

Voltage Varistorvoltage

Surgeresistance

10 to 120 VAC

200 to 240 VAC

380 to 480 VAC 820 to 1,000 VAC

440 to 470 V

240 to 270 V 1,000 A min.

(%'%"

When an L load, such as a solenoidor electromagnetic valve is con-nected, connect a diode that preventscounter-electromotive force. If thecounter-electromotive force exceedsthe withstand voltage of the SSR out-put element, it could result in damageto the SSR output element. To pre-vent this, insert the element parallelto the load, as shown in the followingdiagram and table.

Load

INPUT

As an absorption element, the diode isthe most effective at suppressing thecounter-electromotive force. The re-lease time for the solenoid or electro-magnetic valve will, however, increase.Be sure to check the circuit before use.To shorten the time, connect a Zenerdiode and a regular diode in series.The release time will be shortened atthe same rate that the Zener voltage(Vz) of the Zener diode is increased.

• Absorption Element example

(Reference)

1. Selecting a DiodeWithstand voltage = VRM Powersupply voltage × 2Forward current = IF load current

2. Selecting a Zener DiodeZener voltage = Vz SSRwithstand voltage – (Power supplyvoltage + 2 V)Zener surge power = PRSM Vz ×Load current × Safety factor (2 to 3)

Note: When the Zener voltage is in-creased (Vz), the Zener diodecapacity (PRSM) is also in-creased.

The SSR connects directly to the Prox-imity Sensor and Photoelectric Sensor.

)#"*

*

)+",#+*

Note: 1. The voltage between theload terminals of eitherSSR 1 or SSR 2 turnedOFF is approximately twiceas high as the supply volt-age due to LC coupling. Besure to apply an SSR mod-el with a rated output volt-age of at least twice thesupply voltage.

For example, if the motoroperates at a supply volt-age of 100 VAC, the SSRmust have an output volt-age of 200 VAC or higher.

2. Make sure that there is atime lag of 30 ms or more toswitch over SW1 and SW2.

&*

(Brown)

(Black)

(Blue)

Sensor

Inputsignalsource

Input signalsource andTemperatureController

Loadheater

Motor

Load

pow

er s

uppl

yLo

ad p

ower

sup

ply

Load

pow

er s

uppl

yLo

ad p

ower

sup

ply

LOADINPUT

INPUT LOAD

Incandes-cent lamp

Sensors: TL-X Proximity SensorE3S Photoelectric Sensor

LOADINPUT

SSR

SSR

SSR

SSR

SSR

1

2

INPUT

INPUT

SW1

SW2

25

%'%#,#+*

)+#,#+*

Make sure that signals input into theSSR Units are proper if the SSR Unitsare applied to the forward and reverseoperation of a three-phase motor. IfSW1 and SW2 as shown in the follow-ing circuit diagram are switched oversimultaneously, a phase short-circuitwill result on the load side, which maydamage the output elements of theSSR Units. This is because the SSRhas a triac as an output element that isturned ON until the load current be-comes zero regardless of the absenceof input signals into the SSR.

Therefore, make sure that there is atime lag of 30 ms or more to switchover SW1 and SW2.

The SSR may be damaged due tophase short-circuiting if the SSR mal-functions with noise in the input circuitof the SSR. To protect the SSR fromphase short-circuiting damage, theprotective resistance R may be in-serted into the circuit.

The value of the protective resistanceR must be determined according to thewithstanding inrush current of theSSR. For example, the G3NA-220Bwithstands an inrush current of 220 A.The value of the protective resistanceR is obtained from the following.

R > 220V x /200A = 1.4

Considering the circuit current andweld time, insert the protective resist-ance into the side that reduces the cur-rent consumption.

Obtain the consumption power of theresistance from the following.

P = I2R x Safety factor(I = Load current, R = Protective resist-ance, Safety factor = 3 to 5)

2

Input signalsource SSR

SSR

1

2

M

INPUT

INPUT

LOAD

LOAD

R

S

T

Three-phasepowersupply

SSR

SSR

1

2

INPUT

INPUT

SW1

SW2

INPUT

INPUT

SSR3

SSR4

R

S

T

R

A

LOAD

LOAD

LOAD

LOAD

M

The following provides exam-ples of the inrush currents fordifferent loads.

• AC Load and Inrush Current

causing damage. For switching of all-metal and ceramic heaters, select aPower Controller (G3PX) with a longsoft-start time, or a constant currenttype switch.

TemperatureController(voltage-out-put type)

Heater load

")#"

Inru

sh c

urre

nt

Nor

mal

cur

rent

Solenoid

Load

Incan-descentlamp

Motor Relay CapacitorResis-tanceload

Approx.10times

Approx. Approx. Approx. Approx.

timestimestimes

times

10 to15

5 to 10 2 to 3 20 to50

1Inrush

current

current/Normal

1. Heater Load (Resistance Load)

Load without an inrush current. Gen-erally used together with a voltage-output temperature controller forheater ON/OFF switching. Whenused with an SSR with zero crossfunction, suppresses most noise gen-erated. This type of load does not,however, include all-metal and ce-ramic heaters. Since the resistancevalues at normal temperatures of all-metal and ceramic heaters are low,an overcurrent will occur in the SSR,

2. Lamp Load

Large inrush current flows through in-candescent lamps, halogen lamps,and so on (approx. 10 to 15 timeshigher than the rated current value).Select an SSR so that the peak valueof inrush current does not exceed halfthe inrush current resistance of theSSR. Refer to “Repetitive” (indicatedby dashed lines) shown in the follow-ing figure. When a repetitive inrushcurrent of greater than half the inrushcurrent resistance is applied, the out-put element of the SSR may be dam-aged.

Inru

sh c

urre

nt (

A. P

eak)

Non-repetitive

Repetitive

Power supply time (ms)

3. Motor Load

When a motor is started, an inrushcurrent of 5 to 10 times the rated cur-rent flows and the inrush currentflows for a longer time. In addition tomeasuring the startup time of the mo-tor or the inrush current during use,ensure that the peak value of the in-rush current is less than half the in-rush current resistance when select-ing an SSR. The SSR may be dam-aged by counter-electromotive forcefrom the motor. So when the SSR isturned OFF, be sure to install over-current protection.

26

4. Transistor Load

When the SSR is switched ON, anenergizing current of 10 to 20 timesthe rated current flows through theSSR for 10 to 500 ms. If there is noload in the secondary circuit, the en-ergizing current will reach the maxi-mum value. Select an SSR so thatthe energizing current does not ex-ceed half the inrush current resis-tance of the SSR.

5. Half-wave Rectifying Circuit

AC electromagnetic counters and so-lenoids have built-in diodes, which actas half-wave rectifiers. For thesetypes of loads, a half-wave AC volt-age does not reach the SSR output.For SSRs with the zero cross func-tion, this can cause them not to turnON. Two methods for counteractingthis problem are described below.

(a)Connect a bleeder resistance withapproximately 20% of the SSR loadcurrent.

(b)Use SSRs without the zero crossfunction.

6. Full-wave Rectified Loads

AC electromagnetic counters and sole-noids have built-in diodes which act asfull-wave rectifiers. The load currentfor these types of loads has a rectan-gular wave pattern, as shown in thediagram which follows.

Connect the bleeder resistance R inparallel to increase the SSR switchingcurrent.

Load (relays etc.) release voltageLoad (relays etc.) release current

R <E

IL–IE: Load (relays etc.)

reset voltageI: Load (relays etc.)

reset current

Bleeder resistance standards:100-VAC power supply, 5 to 10 kΩ, 3 W200-VAC power supply, 5 to 10 kΩ,15 W

Accordingly, AC SSRs use a triac(which turns OFF the element onlywhen the circuit current is 0 A) in theoutput element. If the load current wa-veform is rectangular, it will result in aSSR reset error. When switching ONand OFF a load whose waves are allrectified, use a -V model or Power MOS FET Relay.

-V model SSRs: G3F-203SL-VG3H-203SL-V

Power MOS FET Relay: G3DZ, G3RZG3FM

∆V/∆T = dV/dt: voltage increase ratio

7. Small-capacity Loads

Even when there is no input signal tothe SSR there is a small leakage cur-rent (IL) from the SSR output (LOAD).If this leakage current is larger thanthe load release current the SSR mayfail to reset.

8. Inverter Load

Do not use an inverter-controlled power supply as the load power supplyfor the SSR. Inverter-controlled wave-forms become rectangular, so the dV/dt ratio is extremely large and the SSRmay fail to reset. An inverter-controlledpower supply may be used on the in-put side provided the effective voltageis within the normal operating voltagerange of the SSR.

9. Capacitive Load

The supply voltage plus the chargevoltage of the capacitor is applied toboth ends of the SSR when it is OFF.Therefore, use an SSR model with aninput voltage rating twice the size ofthe supply voltage.

Limit the charge current of the capaci-tor to less than half the peak inrushcurrent value allowed for the SSR.

Bleeder resistance

Load

Circuit currentwave pattern

Load

Bleeder resistance R

Load

pow

er s

uppl

y

Load

Voltage increase ratio The dV/dt ratio tends to infinity, so the SSR will notturn OFF.

27

)&+"

If the load power supply is used undervoltage below the minimum operatingload voltage of the SSR, the loss timeof the voltage applied to the load willbecome longer than that of SSR oper-ating voltage range. See the followingload example. (The loss time is A < B.)

%

-"

A leakage current flows through asnubber circuit in the SSR even whenthere is no power input. Therefore, al-ways turn OFF the power to the inputor load and check that it is safe beforereplacing or wiring the SSR.

Switch element Snubber circuit

Inpu

t circ

uit

Trig

ger

circ

uit

Var

isto

r

Leakagecurrent

trigger voltage

Trigger voltage Trigger voltage

100 VAC (R load)trigger voltage

24 VAC (R load)trigger voltage

triggervoltage

quick-break fuse current-limiting fea-ture (IF), and the load inrush current(IL), shown in the following chart.

%+

A short-circuit current or an overcur-rent flowing through the load of theSSR will damage the output elementof the SSR. Connect a quick-breakfuse in series with the load as anovercurrent protection measure.

Pea

k cu

rren

t (A

)

Time (unit: s)

Inpu

t ter

min

al

Inpu

t circ

uit

Inpu

t ind

icat

or

Out

put c

ircui

t

Out

put t

erm

inal

%

The operation indicator turns ONwhen current flows through the inputcircuit. It does not indicate that theoutput element is ON.

,

*

The SSR is an optimum relay for high-frequency switching and high-speedswitching, but misuse or mishandlingof the SSR may damage the elementsand cause other problems. The SSRconsists of semiconductor elements,and will break down if these elementsare damaged by surge voltage orovercurrent. Most faults associatedwith the elements Xare short-circuitmalfunctions, whereby the load cannotbe turned OFF.

Therefore, to provide a fail-safe fea-ture for a control circuit using an SSR,

design a circuit in which a contactoror circuit breaker on the load powersupply side will turn OFF the loadwhen the SSR causes an error. Donot design a circuit that only turnsOFF the load power supply with theSSR. For example, if the SSRcauses a half-wave error in a circuitin which an AC motor is connectedas a load, DC energizing may causeovercurrent to flow through the motor,thus burning the motor. To preventthis from occurring, design a circuit inwhich a circuit breaker stops overcur-rent to the motor.

*".

If G3NA or G3NE SSRs are to bemounted directly onto the control panel,without the use of a radiator, be sure touse a panel material with low thermalresistance such as aluminum or steel.Do not mount the SSR on a panel withhigh thermal resistance such as a panelcoated with paint. Doing so will decreasethe radiation efficiency of the SSR, caus-ing heat damage to the SSR output ele-ment. Do not mount the SSR on a panelmade of wood or any other flammablematerial. Otherwise the heat generatedby the SSR will cause the wood to car-bonize, and may cause a fire.

Location Cause Result

Input area

Output area

Whole Unit

Overvoltage

Overvoltage

Overcurrent

Ambient temperatureexceeding maximum

Poor heat radiation

Input element damage

Output element damage

Output element damage

Design a circuit so that the protectioncoordination conditions for the quick-break fuse satisfy the relationship be-tween the SSR surge resistance (IS),

)

If a DC load power supply is used forfull-wave or half-wave rectified AC cur-rents, be sure that the peak load cur-rent does not exceed the maximumusage load power supply of the SSR.Otherwise, overvoltage will cause dam-age to the output element of the SSR.

Peak voltage

SSR operatingvoltage maximumvalue

%".&)

The operating frequency range forAC load power supply is 47 to 63 Hz.

Make sure that this loss time will notcause problems, before operating theSSR.If the load voltage falls below the trig-ger voltage the SSR will not turn ON,so be sure to set the load voltage to 24VAC minimum. (Except for G3PA-VDand G3NA-2B.)

28

The SSR is not subject to mechanicalwear. Therefore, the life expectancy ofthe SSR depends on the rate of inter-nal component malfunction. For ex-ample, the rate for the G3M-202P is321 Fit (1 Fit = 10–9 = λ (malfunctions/time)). The MTTF calculated from thisvalue is as follows:

MTTF = 321 /λ60 = 3.12 x 106 (time)

The effects of heat on the solder alsoneed to be considered in estimatingthe total life expectancy of the SSR.The solder deteriorates due to heat-stress from a number of causes. OM-RON estimates that the SSR beginsto malfunction due to solder deteriora-tion approximately 10 years after it isfirst installed.

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