Types of Electromechanical Relays |

Electromechanical Relay Working Principle

An electromechanical relay is a device that controls one electrical circuit by opening and
closing contacts in another circuit. Depending on design, relays normally do not control
power-consuming devices directly, except for small loads which draw less than 15 A.

Electromechanical Relays have traditionally been used in machine tool control,

industrial assembly lines, and commercial equipment. Relays are used to switch starting
coils in contactors and motor starters, heating elements, pilot lights, audible alarms, and
some small motors (less than 1/8, HP).

A small voltage applied to a relay results in a larger voltage being switched. See Figure
1. For example, applying 24 V to the relay coils may operate a set of contacts that
control a 230 V circuit. In this case, the relay acts as an amplifier of the voltage or
current in the control circuit because relay coils require a low current or voltage to
switch, but can energize larger currents or voltages.
 Figure 1. Relays may be compared to amplifiers in that small voltage input results in
large voltage output.

Another example of an electromechanical relay providing an amplifying effect is when

a single input to the relay results in several other circuits being energized. See Figure 2.
An input may be considered amplified because certain mechanical relays provide eight
or more sets of contacts controlled from any one input.

Figure 2. Relays may be compared to amplifiers in that a single input may result in
multiple outputs.

The two major types of relays are the electromechanical relay and the solid-state
relay. An electromechanical relay (EMR) is a switching device that has sets of contacts
that are closed by a magnetic effect. A solid-state relay (SSR) is a switching device that
has no contacts and switches entirely by electronic means.
Types of electromechanical relays

Electromechanical relays that are common to commercial and industrial applications

may be general-purpose, machine control, or reed relays. The major differences
between the types of electromechanical relays are their intended use in the circuit, cost,
and life expectancy of each device.

General-Purpose Relays

A general-purpose electromechanical relay is a mechanical switch operated by a

magnetic coil. See Figure 3. General-purpose relays are available in AC and DC
designs. These electromechanical relays are available with coils that can open or close
contacts ranging from millivolts to several hundred volts.

Relays with 6 V, 12 V, 24 V, 48 V, 115 V, and 230 V coils are the most common.
General-purpose electromechanical relays are available that require as little as 4mA at
5VDC or 22mA at 12VDC.These relays are available in a wide range of switching
configurations.

Figure 3. A general-purpose relay is a mechanical switch operated by a magnetic coil.

General-purpose relays are electromechanical relays that include several sets (normally
two, three, or four) of non-replaceable NO and NC contacts (normally rated at 5 A to 15
A) that are activated by a coil. See Figure 4.

A general-purpose relay is a good relay for applications that simplify troubleshooting

and reduce costs. Special attention must be given to the contact current rating when
using general-purpose relays because the contact rating for switching DC is less than
the contact rating for switching AC. For example, a 15 A AC-rated contact normally is
only rated for 8 A to 10 A DC.
Figure 4. General-purpose relays are electromechanical relays that include several sets
of non-replaceable NO and NC contacts that are activated by a coil.

General-purpose electromechanical relays are designed for commercial and industrial

applications where the economy and fast replacement are high priorities. Most general-
purpose relays have a plug-in feature that makes for quick replacement and simple
troubleshooting. Because they are inexpensive, they are thrown away rather than
replaced.

Contacts.

 Contacts are the conducting part of the relay that acts as a switch to make or break a
circuit. The most common contacts are the single-pole, double- throw (SPDT); double-
pole, double-throw (DPDT); and the three-pole, double-throw (3PDT) contacts. Relay
contacts are described by their number of poles, throws, and breaks. See Figure 5.
 Figure 5. Relay contacts are described by their number of poles, throws, and breaks.

A pole is the number of completely isolated circuits that a relay can switch. A single-
pole contact can carry current through only one circuit at a time. A double-pole contact
can carry current through two circuits simultaneously.

In a double-pole contact, the two circuits are mechanically connected to open or close
simultaneously and are electrically insulated from each other. The mechanical
connection is represented by a dashed line connecting the poles. Relays are available
with 1 to 12 poles.
A throw is the number of closed contact positions per pole. A single-throw contact can
control only one circuit. A double-throw contact can control two circuits.

A break is the number of separate places on a contact that open or close an electrical
circuit. For example, a single-break contact breaks an electrical circuit in one place.

A double-break (DB) contact breaks the electrical circuit in two places. All contacts are
the single break or double break. Single-break (SB) contacts are normally used when
switching low-power devices such as indicating lights. Double-break contacts are used
when switching high-power devices such as solenoids.

Tech Tip

A relay contact block may contain more contacts than are required for a particular
application. Unused relay contacts can be connected in parallel with the used contacts
to divide the current flow over both sets of contacts. Contact life can be extended
because dividing the current flow over multiple sets of contacts reduces the current flow
through any one set.

Electromechanical Relay manufacturers use a common code to simplify the

identification of relays. See Figure 6. This code uses a form letter to indicate the type of
electromechanical relay.

For example, Form A has one contact that is NO and closes (makes) when the coil is
energized. Form B has one contact that is NC and breaks (opens) when the coil is
energized. Form C has one pole that first breaks one contact and then makes a second
contact when the coil is energized. Form C is the most common form.

In some electrical applications, the exact order in which each contact operates (makes
or breaks) must be known so the circuit can be designed to reduce arcing. Arcing
occurs at any electrical contact that has current flowing through it when the contact is
opened.
Figure 6. Relay manufacturers use a common code (form letter) to simplify the
identification of relays.
Machine Control Relays

A machine control relay is an electromechanical relay that includes several sets (usually
two to eight) of NO and NC replaceable contacts (typically rated at 10 A to 20 A) that
are activated by a coil. Machine control relays are the backbone of electromechanical
control circuitry and are expected to have a long life and a minimal amount of problems.

Machine control electromechanical relays are used extensively in machine tools for
direct switching of solenoids, contactors, and starters. See Figure 7. Machine control
electromechanical relays provide easy access for contact maintenance and may provide
additional features like time delay, latching, and convertible contacts for maximum
circuit flexibility.

Convertible contacts are mechanical contacts that can be placed in either a NO or NC

position. Machine control relays are also known as heavy-duty or industrial control
relays.

Figure 7. Machine control relays are used extensively in machine tools for direct
switching of solenoids, contactors, and starters.

In a machine control electromechanical relay, each contact is a separate removable unit

that may be installed to obtain any combination of NO and NC switching. These
contacts are also convertible from NO to NC and from NC to NO. See Figure 8.
The unit may be used as either a NO or NC contact by changing the terminal screws
and rotating the unit 180°. Relays of 1 to 12 contact poles are readily assembled from
stock parts. Machine control relays may have additional decks (groups of contacts)
stacked onto the base unit.
 Figure 8. Machine control electromechanical relay contacts are convertible from NO to
NC and from NC to NO.

The control coils for machine control relays are easily changed from one control voltage
to another and are available in AC or DC standard ratings.

Machine control relays have a large number of accessories that may be added to the
relay unit. These include indicating lights, transient suppression, latching controls, and
time controls.

Reed Relays

A reed relay is an electromechanical relay which is fast-operating, single-pole, single-

throw switch with normally open (NO) contacts hermetically sealed in a glass envelope.
See Figure 9.

During the sealing operation, dry nitrogen is forced into the tube, creating a clean inner
atmosphere for the contacts. Because the contacts are sealed, they are unaffected by
dust, humidity, and fumes. The life expectancy of reed type electromechanical relay
contacts is quite long.
 Figure 9. A reed relay is a fast-operating, single-pole, single- throw switch that is
activated by a magnetic field.

A reed relay includes a very low current-rated contact (less than 400 mA) that is
activated by the presence of a magnetic field. Reed relays may be activated in a variety
of ways, which allows them to be used in circuit applications where other
electromechanical relay types are inappropriate.

Reed relays are designed to be actuated by an external movable permanent magnet or

DC electromagnet. When a magnetic field is brought close to the two reeds, the
ferromagnetic (easily magnetized) ends assume opposite the attracting force of the
opposing poles overcomes the stiffness of the reed, drawing the contacts together.
Removing the magnetizing force allows the contacts to spring open. AC electromagnets
are not suitable for reed relays because the reed relay switches so fast that it would
energize and de-energize on alternate half-cycles of a standard 60 Hz line.

Reed Contacts.

 To obtain a low and consistent contact resistance, the overlapping ends of the contacts
may be plated with gold, rhodium, silver alloy, or other low-resistance metal. Contact
resistance is often under 0.1 Ω when closed. Reed contacts have an open contact
resistance of several million ohms.

Most reed contacts are not directly capable of switching of industrial solenoids,
contactors, and motor starters. Reed relay contact ratings indicate the maximum
current, voltage, and volt-amps that may be switched by the relay. Under no
circumstances should these values be exceeded.

Tech Tip

Reed relays are operated by a magnetic field. Unshielded relays (the least expensive
type) that are placed close to each other can cause false relay operation. Shielded
relays should be used when the relays must be located near each other or when
magnetic fields from motors and transformers may cause false operation.

Reed Relay Actuation.

A permanent magnet is the most common actuator for a reed relay. Permanent- magnet
actuation can be arranged in several ways depending on the switching requirement.
One of the most commonly used arrangements is proximity motion.

The proximity motion arrangement uses the presence of a magnetic field that is brought
within a specific proximity (close distance) to the reed relay to close the contacts. The
distance for activating any given electromechanical relay depends on the sensitivity of
the relay and the strength of the magnet.

A more sensitive relay or stronger magnet needs less distance for actuation. Methods of
proximity motion operation are the pivoted motion, perpendicular motion, parallel
motion, and front-to-back motion. See Figure 10. In each method, either the magnet or
relay is moved.

In some applications, both the magnet and relay are in motion. The contacts operate
quickly, with the snap action and little wear. The application and switching requirements
determine the best method.
Figure 10. The proximity motion arrangement uses the presence of a magnetic field
brought within a specific proximity to the reed relay to close the contacts.
Electro Mechanical Relays

Electromechanical Relays

Electromechanical relays are switches that typically are used to control high power
electrical devices. Electromechanical relays are used in many of today's electrical
machines when it is vital to control a circuit, either with a low power signal or when
multiple circuits must be controlled by one single signal. Electromechanical relays
contain electronic parts that make it possible to operate them for many different
applications. They are used mostly in the general aviation, aerospace, and wireless
technology industries, but they have many other applications as well. In fact, thousands
of electrical devices require electromechanical relays to make them work. But exactly
what is an electromechanical relay, and what types of relays are in use today?

Definition

An electromechanical relay, put simply, is a switch. An electrically operated switch to

be exact. Relays are electrical parts that are used when a low-power signal is needed in
order to control a circuit, or when a number of circuits need to be controlled by one
signal. There are several different types of electromechanical relays, and which type is
used depends on the specific mechanical device it is used in. Some relays require an
electromagnet, or a magnet in which a magnetic field is produced by electric current,
with the magnetic field disappearing when the current is switched off. (Of course, an
electric current is the flow of a charge of electricity.) A relay that can control higher
powered devices, such as for an electric motor, is called a 'contactor.'

History

Relays were first developed back in the 1800s when it became necessary to use them
for electrical protection. In the 1980s, static relays became the norm, and mechanical
relays were being replaced by them. Static relays operated with analog circuitry and
were considered more straightforward, as they had no moving parts. Digital relays are
now replacing older types of relays. They are more accurate and reliable, since they use
microprocessors that use numeric systems of counting, which are more exact.
Electromechanical relays are considered the basis of electrical protection systems.
Even though electromechanical relays are being replaced in some instances with
microprocessors which are number-based devices, there still are a lot of relays in use
today. The very first electromechanical relays were invented and used in circuits for
long-distance telegraph as means of amplifying. These relays repeated the signal that
came in from one circuit and then transmitted it on to a second circuit.
Electromechanical relays were most commonly used in the first computers and also in
telephone exchanges in order to perform logical computations and operations.

How Electromechanical Relays work

Relays are typically used when it is necessary to switch a small amount of power to a
larger amount of power. Relays contain several electronic parts to make them work.
These include an electromagnet, which controls opening and closing of the relay. Next
is the armature, or the moving part, which is the electronic part that opens and closes. A
spring is also used in a relay. This is the part that forces the relay back to its original
position after each revolution. In addition, a set of electrical contacts is needed in order
to transfer the power.

Uses

The point of a relay is to use a small amount of power to switch to a large amount of
power. Relays typically are used in modern household appliances such as hair dryers,
kitchen appliances, and lights that need to be switched on and off. They are also used
in cars where things need to be turned off and on. In fact, modern car manufacturers
are using relay panels in fuse boxes because they make maintenance simpler. There
are a few things to think about when selecting relays for modern devices. First, you
need to consider whether the contact will be normally closed (NC) or normally open
(NO). Each of these situations will dictate which types of relays are needed and whether
the device needs to be on all the time or needs to be toggled between the on and off
positions. Another thing that must be considered is the maximum amount of voltage that
the armature and its contact devices can handle. Finally, and perhaps the most
important consideration, is the voltage and current that will be needed in the electronics
project being undertaken because this will determine the armature activation.

Electromechanical Relay
An electromechanical relay is an electrical switch that is typically
operated by using electromagnetism to operate a mechanical switching
mechanism.

An electrical relay is an electromagnetically operated electrical switch - an

electromechanical switch. A relatively small current is used to create a magnetic field in
a coil within a magnetic core and this is used to operate a switch that can control a
much larger current.

In this way an electromechanical relay or electrical relay can use a small current to
switch a much larger current and enable both circuits to be electrically isolated from
each other.

Electrical relays come in a variety of different sizes and they can be of a variety of
different types using slightly different technologies, although they all use the same basic
concept.

Although electromechanical relays may be considered in some respects to use old

technology, and solid state relays / solid state switches might be thought to be a more
effective means of switching electrical current.

Nevertheless, electromechanical relays have some unique properties that make them
ideal for many applications, where other types may not be as effective. That said, solid
state switches, solid state relays or electronic switches are widely used and have taken
over in many areas where electromechanical relays were previously used as electrical
switches.
Relay circuit symbol
The circuit symbols for electromechanical relays can vary somewhat - like most circuit
symbols. The most widely used format shows the relay coil as a box, and the contacts
are placed close by as shown below.

Circuit symbol of a relay

Note that on this symbol, both normally open and normally closed contacts are shown.
Where one or more sets of contacts is not used, it is often not shown.

Other circuits, especially new that may be a bit older may show the relay coil as an
actual coil. Although this does not conform to the latest relay circuit symbol standards, it
may nevertheless be seen in some instances and it describes the inside of the relay
well.

Circuit symbol of a relay

An older style showing the relay coil.

It is possible for there to be further sets of electrical switch contacts. In the same way
that it is possible to have multiple poles on a switch, the same can be done with relays.
It is possible to have several sets of switch contacts to change over multiple circuits.

Circuit symbol of a relay

An older style showing the relay coil.

Relay switch basics
A relay is a form of electrical switch that is operated by electromagnet which changes
over the switching when current is applied to the coil.

These relays may be operated by switch circuits where the switch cannot take the high
current of the electrical relay, or they may be operated by electronic circuits, etc. In
either circumstance they provide a very simple and attractive proposition for electrical
switching.

Basic concept of an electrical relay switch operation

Relays have a number of basic parts that form the relay.

 Frame: A mechanical frame is required to hold the components in place. This

frame is normally quite robust so that it can firmly support the additional elements
of the electromechanical relay without relative movement.
 Coil: A coil wound round an iron core to increase the magnetic attraction is
needed. The coil of wire causes an electromagnetic field to be created when the
current is switched on an causes the armature to be attracted.
 Armature: This is the moving part of the relay. This element of the relay opens
and closes the contacts and it has a ferromagnetic metal to be attracted by the
electromagnet. The assembly has an attached spring which returns the armature
to its original position.
 Contacts: The contacts are operated by the action of the armature movement.
Some of the electrical switching contacts may close the circuit when the relay is
activated where as others may open a circuit. These are known as normally open
and normally closed.

Relay design involves a number of aspect. It is a key element of the design to obtain the
required magnetic flux to attract the armature sufficiently quickly, without consuming
excessive current. Also it is necessary to ensure that the relay can open quickly once
the energizing current is removed. Magnetic retention in the materials needs to be low.

When a current flow through the coil an electro-magnetic field is set up. The field
attracts an iron armature, whose other end pushes the contacts together, completing
the circuit. When the current is switched off, the contacts open again, switching the
circuit off.

When specifying electromechanical relays, it will be seen that the electrical switch
contacts come in a variety of formats. Like ordinary electrical switches,
electromechanical relays are defined in terms of breaks, poles and throws that the
device has.
  Break:   Whilst may of the terms applied to electromechanical relays also apply
to low power electrical switches, this one is more applicable to higher power
switching. It is the number of separate places or contacts where a switch is used
to open or close a single electrical circuit.

All relays are either single break or double break. A single break, SB contact
breaks an electrical circuit in only one place. Then as the name indicates, a
double break, DB contact breaks the circuit in two places.

Single break contacts are normally used when switching lower power devices,
possibly electronic circuits or low power electrical switching applications. Double
break contacts are used for the electrical switching of high power devices. If one
of the contacts sticks, then the other one is likely to still switch and break the
circuit.

 Pole:   The number of poles that an electrical switch posse is the number of
different sets of switching contacts that it has. A single pole switch can only
switch one circuit, whereas a double pole switch can switch two different and
isolated circuits at the same time. A single pole switch is often denoted by the
letters SP, and a double pole by DP. Relays can have one, two or more poles.
 Throw:   The number of throws on an electrical switch is the number of positions
that are available. For an electromechanical relay, there are normally only one or
two throws. A single throw relay will make and break a circuit, whereas a double
throw relay will act as a changeover routing a connection from one end point to a
different one. Single throw and double throw are often denoted by the letters ST
and DT.

For example, an electrical relay specification may quote a single pole, single throw:
SPST or one may be described as double pole single throw: DPST, etc. These terms
enable the number of sets of switch contacts and whether they are an open / close or
whether they provide a change-over function.

Electromechanical relay contacts

In order to provide a reliable service and to maximize the lifetime of the relay. Different
materials are used on the contacts to ensure they operate well for their intended use.

One of the issues that occurs with the contacts is that pitting occurs - typically material
tends to accumulate in the center of one contact, whilst there is a loss of material from
the other where a "pit" occurs. This is one of the major causes of contact failure and
occurs especially where sparks are generated.

Different relays have different types of material used for the switch contacts dependent
upon the applications and the performance required. There are many finished that can
be used, some of the more widely used ones are listed below with their attributes.
  Silver:   In many respects, silver is one of the best general purpose materials for
relay contacts having a high level of conductivity. However, it is subject to a
process of sulphidation which is obviously dependent upon the atmosphere in
which the relay operates - it is much higher in urban areas. This process causes
a thin film on the surface with reduced conductivity, although higher contact
impact at the relay contact closure can break through this. The film can also give
rise to an interface voltage of a few tenths of a volt which can affect the
performance for some applications
 Silver nickel:   This type of contact was developed to reduce the effects of
pitting. The silver contact is alloyed with nickel to give it a fine grain structure and
as a result the material transfer occurs more evenly across the entire surface of
the contact resulting in longer life.
 Silver cadmium oxide:   Contacts made using silver cadmium oxide cannot
equal the very high conductivity of fine silver contacts, but they do offer increased
resistance to material transfer and contact loss as a result of arcing. This means
that these contacts will typically last longer than that of a silver contact under the
same conditions.
 Gold:   The high conductivity and fact that it does not oxidize means that gold is
ideal for many switching applications. It is only used for low current switching as
it is not particularly robust. Typically, gold flashing is used to reduce cost and as
a result of the low levels of sulphidation, the contacts remain in good condition
over long periods. One issue with relays is that if they are not used for some
while the contact resistance can increase - this does not occur with gold.
 Tungsten:   Tungsten is used in relays that are intended for high voltage
applications. Having a high melting point of over 3380°C it has excellent arc-
erosion resistance which is required for this type of switching.
 Mercury:   Mercury is used in a special type of reed relay called a mercury
wetted reed relay. It has good electrical conductivity and as it is a liquid there is
no pitting caused by the transfer of material between the contacts. After the
switch contacts are opened, the mercury returns to the pool of mercury required
for this type of relay and new mercury used for the next switching action. This
action negates the effect of any material transfer during switching.

Although many different types of material and alloy are used, these are most of the
commonly used contact materials and finishes.

Inrush limitation to improve reliability

One of the key issues that is experienced by electrical switching systems:
electromechanical relays as well as solid state switches, is that of inrush current.

There are many examples of how large the levels of inrush current can be. A simple
domestic incandescent electric light bulb illustrates the point well. When cold the
filament has a low resistance, and it is only when the lamp heats up that its resistance
diminishes. Typically, the inrush current at switch on may be ten to fifteen times the
steady state current. Even though solid state lamps are now normally used, this
example serves to illustrate the point well.

Additionally, inductive loads like motors and transformers, which are often switched by
electromechanical relays have a very high inrush current. Often the inrush current can
easily be ten times the steady state current, so the contacts need to be rated
accordingly.

In many areas an allowance is made to accommodate the inrush current. A factor is

used by which the steady state current is multiplied to give the contact rating. A table of
typical multiplication factors is given below.

Common Multipliers Used to Accommodate Inrush Current on Relays

Load to be switched Multiplier
Fluorescent lights (AC) 10
Incandescent light bulbs 6
Motors 6
Resistive heaters 1
Transformers 20

Therefore, using the table below, if fluorescent lights are to be switched and they
normally consume 1 A, then the relay contacts should be rated at 20 A.

A further issue occurs when the circuit is broken. The back EMF generated by the
inductive load can easily lead to sparking which can quickly destroy the relay contacts.

Methods like fitting inrush limiters on the load which are often negative temperature
coefficient resistors can help to limit the inrush current, and transient suppressors can
help limit the back EMF.

Relay operational life

One of the key issues associated with electromechanical relays is that of contact life.
Unlike solid state relays and electronic switches, the mechanical contacts wear with
switching and have a limited life.

Two figures are available for the electromechanical relay lifetime:

 Electrical life expectancy:   The electrical life expectancy is the number of

switching actions that are undertaken whilst the switching, i.e. the contacts,
provide the required level of conductivity. It is very dependent upon the
application as inrush current and back arcing created by back EMF, etc. Many
power relays have an electrical life expectancy of possibly 100 000 operations,
although, as mentioned, this is very dependent upon the load it is switching.
  Mechanical life expectancy:   The mechanical life expectancy is reefers to the
mechanical aspects of the relay. It is the number of mechanical switching actions
that can be undertaken regardless of the electrical performance. Often the
mechanical life expectancy of a relay is around 10 000 000 operations of even
much more.

The end of life for the contacts generally occurs when the contacts stick or weld, or
when the arcing, etc has caused contact burn and transfer of material such that
sufficiently contact resistance cannot be achieved. The conditions for this will depend
upon the relay and its application. They specifications will normally be defined in
datasheet for the relay.

Coaxial relay

See the entry points for the coax cable

Advantages and disadvantages of relays

As with any technology there are advantages and disadvantages to the use of
electromechanical relays. When designing circuit, it is necessary to weight of the
positives

Advantages

 Provides physical isolation between circuits.

 Can usually withstand high voltages.
 Can tolerate short term overloads, often with no or little ill effects - transient
effects can often irreparably damage solid state relays / electronic switches.

Disadvantages

 Mechanical nature of the relay means it is slow when compared to

semiconductor switches.
  Has a limited lifetime due to the mechanical nature of the relay? Solid state
switches tend to have a greater level of reliability provided they are not subject to
transients that fall outside their ratings.
 Suffers from contact bounce as the contacts start to make contact and then
physically bounce, making and breaking the contact and causing some arcing to
a greater or lesser degree.

Sometimes another option that can be considered when requiring electrical isolation
between two circuits may be an opto-isolator. These opto-isolators are often
incorporated into solid state switches, often also called solid state relays ensuing that
high levels of isolation are achieved. The use of opto-isolators in solid state switches /
solid state relays provides complete isolation between the input and output circuit.

Electromechanical relays have been in use for very many years as electrical switches
and the technology is well established. These electromechanical or electrical relays can
tolerate some abuse and they are normally relatively tolerating to transient voltage
surges or spikes. In this respect they are better than solid state switches / solid state
relays and although they wear more quickly, especially when they are switching
inductive loads of they have to tolerate switch on surges in their loads.

As solid state relays and switches are now present in the market and offer high levels of
reliability, the options of electromechanical relays versus solid state relays need to be
carefully considered. In some instances, older relays are being replaced by solid state
relays, but in other instances, electromechanical relays may offer the best option.