Designing with reed relays – Beyond the datasheet

By Keith Moore, CEO, Pickering Electronics

For many switching applications, reed relays remain the superior solution; their small size, high
isolation resistance, hermetically sealed contact surfaces and high life expectancy make them the
best choice over other switching technologies. A reed relay designed with high quality in mind, - with
no compromise on methods or materials - delivers the greatest performance and reliability which is
crucial to end users. The benefits of this for the user are measurable: a reduction in cost of
ownership; longer component life; reduced downtime; and full magnetic screening enabling higher
packing density which reduces system hardware and connectivity.

What is a reed relay?

The fundamental element of a reed relay is the reed switch. It consists of two ferromagnetic,
nickel/iron blades suspended in glass capsule that controls the gap, alignment and overlap. The
opposing contact areas are plated with an appropriate material and the capsule is either filled with
an inert gas or is a vacuum, depending on the application. When a magnetic field is applied to the
blades they become magnetised and are attracted to each other, making contact. In a reed relay, the
current flowing through the turns of the coil produces the required magnetic field to operate the
reed switch. The switch and coil assembly can be mounted onto a lead-frame, along with a
suppression diode across the coil if required. This assembly is fitted into an encapsulation shell
which includes an internal magnetic screen.

A range of factors needs to be considered when selecting the appropriate reed relay for a particular
application. Contact plating and sensitivity, measured in Ampere Turns (AT), are the main factors
that affect the performance.

Reed Switch Contact plating

For instrumentation-grade switches required for precision instrument measurements, there are two
plating options. Historically, the general-purpose switch was plated rhodium but is now generally
sputtered ruthenium with a copper dispersion layer underneath, which is better suited to hot
switching applications, although low level and cold switching performance is still good. The preferred
plating for low level and cold switching where life greater than 1,000 million operations are to be
expected is just sputtered ruthenium. For higher power or high voltage applications, both sputtered
ruthenium and plated rhodium are used along with plated iridium and tungsten in more specialized
fields.

Ampere Turns (AT) Ratings

The Ampere Turns (AT) coefficient is the sensitivity of the switch - it quantifies the magnetic field
required to operate the switch. The AT band is generally proportional to the contact gap: the larger
the gap, the less sensitive the switch and the higher the restoring force is when the closing magnetic
field is removed. The driving coil is designed to give the required current flowing through the
required number of turns to generate a magnetic field strong enough to operate the selected AT
switch along with adequate overdrive to ensure stable operation along with fast operating times.
Coils can be either wound on a bobbin or self-supporting (formerless). A formerless coil has more
winding area when compared to a bobbin coil so more turns can be achieved for the same coil
resistance. This means that relatively higher AT band switches can be used with the dual advantages
of being less sensitive to stray magnetic fields causing magnetic interaction, and higher restoring
forces when the magnetic field is removed on turn off, meaning contactsless likely to stick together
after a short overload.

Standoff voltage ratings

Another advantage of high AT switches and their larger contact gap is that this increases the voltage
stand-off. For reed switches where the contacts are sealed in a vacuum, stand-off voltages of several
1000 volts are possible in a relatively small package.

Magnetic Interaction

When relays are used side by side, extraneous magnetic fields from the coils can significantly affect
the magnetic field each relay produces, and hence affect the operational parameters of the switch.
In a worst-case scenario, without a magnetic screen adjacent relays may be prevented from
operating at their nominal
voltage; even if they do
operate, they may only just
operate with little or no
overdrive which helps to
maintain low and stable
contact resistance.
Incorporating a complete
Mu metal magnetic screen
reduces magnetic
interaction to acceptable
levels and maintains correct
operation.
Hot and cold switching

There are two distinct operational switching methods for reed relays.
Hot switching occurs when the volts and current of the load are present when the contact closes, so
the overall power is switched. Hot switching also occurs when the contact is opened, and the current
flow is broken and the volts rise.
Cold switching occurs when the contact is closed with no volts or current present. Once contacts are
closed and settled, the load is applied and the current only carried. Before the contact is opened, the
load is turned off so there is no current is flowing when the contacts open. This method greatly
improves the life expectancy of the switch when compared to hot switching, especially if the load
voltage or current are relatively high in respect to the switch ratings. In this situation, contact abuse
can happen and operational accidents can occur as a result of power being switched in excess of the
relay ratings, or inrush where capacitance in the circuit is discharged through a closing switch
without any limiting resistance.

Higher AT switches with their higher restoring

forces can be less prone to sticking.
In cold switching applications, the maximum
current that can be continuously carried is limited
by the heating effect on the switch contact surface
from the power dissipated – according to I²R
where I is the current flowing and R is the contact
resistance. However, higher current pulses can be
carried so along as the duty cycle keeps the
dissipated power within acceptable levels.

Magneto-Strictive Twist

An effect of carrying higher current pulses is termed Magneto-Strictive Twist. Current flowing
through the switch creates an opposing field, causing a slight reduction in the energizing force and a
slight twist in the blades. This can alter the contact resistance. Low AT switches are more susceptible
to this effect; higher AT switches are not affected as much by this opposing field, so there is less
twist and resultant change in contact resistance.
Temperature

Temperature can affect the operation of a reed relay in a number of ways. Copper wire used to wind
the coils has a positive temperature coefficient of approximately 0.4% per °C, so the coil resistance
will increase at this level. As the resistance increases, the current and therefore the level of magnetic
field will fall. For example, a relay that operates at 3.5V at +20°C will operate at approximately 4.62V
at +100°C. This needs to be considered if relays are to be used in higher temperature environments.
This example highlights the importance of ensuring that the relay design ensures defined
operate/release voltage windows, which is easier to achieve when using higher AT switch bands.
Another factor that needs to be considered with low level signals is thermal EMF. Where dissimilar
metals are joined and a temperature gradient is present across the relay, a very low voltage will be
generated (µV levels) – named the Seebeck Effect. Relay design should take this into consideration,
using similar metals to reduce voltage generation at joints. Higher coil resistances minimise the
heating effect and optimise the thermal dispersion in the relay body.

Switching reliability

Choosing the most appropriate switch for the application and minimizing hot switching brings
significant improvements to life expectancy. If hot switching is unavoidable, then by ensuring that
the loads are always within the specified ratings and the coil drive voltages are at nominal, and by
keeping the magnetic interaction and temperature effects to within acceptable levels, the relay
should perform at its optimum level.

If the considerations above are understood and implemented a reed relay will be the best choice for
higher performance applications, such as instrumentation, semiconductor test, ATE, high voltage,
low capacitance/attenuation, low thermal and others.