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D-U200-W

4 Contacts safety critical relay


Features
 Compact plug-in design  Instantaneous, 4 NO/NC contacts  Standard back EMF diode Magnetic arc blow-out.  Flat, square silver plated relay pins for excellent socket connection  Wide range sockets  Integrated snap lock  Transparent cover  High DC breaking capacity  Flexibility by many options Positive mechanical keying relay to socket Weld-no-transfer (WNT) contacts

EN 5 0 5 20

Benefits
 Proven reliable  Long term availability  Easy to maintain Suitable for safety critical applications Low life cycle cost No maintenance

Railway compliancy

Application
Rugged plug-in relay for extreme reliable safety critical, long endurance applications in harsh environment. Proven reliable operation in switching high DC voltage/inductive loads and low currents. Compact design, choice of many options and a wide range of sockets make the D-U200 relay an easy and flexible solution to use.

Description
The relay series are designed for demanding train borne applications such as doorcontrol and standard equipped with weld-no-transfer contacts. The construction of the relay and choice of materials make the D-U200 relay suitable to withstand corrosive atmospheres, low and high temperatures, shock and vibration and dry to very humid environments. No external retaining clip needed as integrated snap-lock will hold relay into socket under all circumstances and mounting directions. All relays are standard equipped with a magnetic arc blow-out (for high breaking capacity and long contact life) and a back EMF suppression diode.

 EN 50155 Electronic equipment used on rolling stock for railway applications  IEC 60571 Electronic equipment used on railway vehicles  IEC 60077 Electrical equipment for rolling stock in railway applications  IEC 60947 Low voltage switch gear and control gear  IEC 61373 Rolling stock equipment Shock and vibration test  EN 50121 Electromagnetic compatibility for railway applications  NF F16-101/102, TS 45545-2 Fire behaviour - Railway rolling stock  IEC 60529 European standard describes the protection class (IP-code) IEC 60068-2  EN 50205 Relays with forcebly guided (mechanically linked) contacts  NFF 62002 On-off contact relays and fixed connectors

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D-U200-W

Technical specifications

Connection diagrams, available models


Bottom view relay D-U200-W013 relay contact combination 1 NC 3 NO

D-U200-W022 relay contact combination 2 NC 2 NO D-U200-W031 relay contact combination 3 NC 1 NO

No connection pins are placed at the black marked pin positions.

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Top view socket

Note: For applications in France the relay and correct socket form a obligatory combination. Additional standard keying see page 13

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At the black marked positions the holes in the socket are blocked, so no relay pin can enter. Only correct contact configuration of the D-U200-W0XX model will fit.

D-U200-W

Technical specifications
Timing diagram

Coil data DC versions


Operating times at nominal voltage Pull-in time Release Time Bounce time NO contacts Bounce time NC contacts Operating voltage range < 25 msec. 55 msec. 5 msec. 16 msec. 0.7 - 1.25Unom Inductance L/R at U nom energized released 11 ms 8 ms

Nom. power consumption 2.2W@Unom

Min drop out voltage

see table below

The coil resistance of the D-U20.. relay is measured at room temperature and has a tolerance of + 10%. Coil designed for permanent energization. Type
D-U201 D-U202 D-U203 D-U204 D-U205 D-U206 D-U207

Unom (VDC)
24 48 72 110 96 12 36

Umin (VDC)
16.8 33.6 50.4 77 67.2 8.4 25.2

Umax (VDC) Udrop out(VDC) Rcoil-nom () Icoil-nom (mA)


30 60 90 137.5 120 15 45 2.5 4.8 7.2 11 9.5 1.2 3.5 270 1103 2406 5330 4400 72 562 89 44 30 21 22 167 64

U pull-in and U drop-out may vary 10% when changing the orientation of the relay. Umin is guaranteed.

Operating range at various temperatures


2,5 Voltage/U-nom [%] 2 1,5 1 0,5 0
Umax

U -pull in U-hold up -40 -20 0 20 Temperature [ C] 40 60 80

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D-U200-W

Technical specifications
Contact data
Maximum make current Maximum continuous current Maximum switching voltage Peak inrush current Min. switching voltage/current Contact resistance Maximum breaking capacity Maximum breaking capacity Material Contact gap Insulation between open contacts Contact force 16 A 10 A (AC1 ; IEC 60947) 250 VDC, 440 VAC 200 A (withstand > 10 x 200 A @ 10 ms, 1 min) 12 V, 10 mA 15 m (initial) 110 V, 10 A (L/R 15 ms) 230 V, 10 A (cosj 0.7) Ag standard (optional AgSnO2, Au on Ag) > 1.5mm. 2.5 kV ; 50 Hz ; 1 min > 200 mN

DC AC

Electrical characteristics
Dielectric strength Pole-Pole Cont-Coil Pulse withstanding EN 50155 IEC 60055-5/ IEC 60077 IEC 60255-5 4 kV, 50 Hz, 1 min 2.5 kV, 50 Hz, 1 min 5 kV (1.2/50 s)

Mechanical characteristics
Vibration & shock Mechanical life Rated switching frequency Weight Temperature Humidity Protection Materials Electronic components IEC 61373 Category I, Class B Body mounted 10 x 106 (tests are ongoing to confirm 30 x 106) 1200 ops/h 140 g +70 C -25 C (option C = -50 C) 95% (temporary permitted condensation) IP 40 Polycarbonate / Polyester (non toxic. fire resistant) Back EMF protection diode BYW56

Tamb, max Tamb, min

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D-U200-W

Technical specifications
Dimensions (mm.)

40

53
1 2

3 4

5 6

7 8

9 10

11 12

13 14

Options
Code
C E K L M N P Q T Y X2 Z

Description
Low temperature (-50C) Au; Gold plated contacts (10 m) Extra dust protection LED integrated in coil AgSnO2; non-weldable contacts No magnetic arc blow-out Polarisation diode Double zener diode over coil Push to test button Double make / double break (-50C) AC / DC rectifier bridge No diode

Remark
Icontact < 8 A

Cannot be combined with:


M T

Icontact > 100mA

2 CO DMDB
Polarity independent

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D-U200-W

Technical specifications
Environmental characteristics
Environmental Operating temperature Vibration, long life EN50125-1 and IEC60077-1 -25oC to +70oC (-50oC when using option C) IEC 61373, Section 9, Table 2, Category 1, Class B, Body Mounted. Random vibration test for 5 hours in each of the 3 mutually perpendicular axes. Total vibration time 15 hours. IEC 61373, Section 8, Table 1, Category 1, Class B, Body Mounted. Random vibration test for 30 minutes in each of the 3 mutually perpendicular axes. Total vibration time 90 minutes. IEC 61373, Par. 10, Table 3, Category 1, Classes A & B, Body Mounted. The relays were monitored during this test and powered at 100% of their rated current. The relays were securely fastened to the table of the shock. The relays were subjected to a total of 18 shock pulses, 3 pulses in each direction of the 3 mutually perpendicular axes. Each shock pulse approximated a half-sine wave of 5g (50 m/s2) with a nominal time duration of 30 milliseconds. IEC 60068-2-11, Test Ka, with the following details. Prior to the start of the Salt Mist Test a sufficient amount of 5% salt solution was prepared for the test. The pH of the solution was maintained between 6.5 and 7.2. The volume of salt solution collected on an 80 sq cm area was maintained between 1.0 and 2.0 ml per hour. The test chamber is conditioned at 35C2C The relays were subjected to a salt spray period of 96 hours. At the completion of the salt mist period the relays were rinsed and dryed during 1 to 2 hours. After this, the relays were visually examined for corrosion and external physical damage. The relays were then subjected to the dielectric withstanding voltage test and contact resistance test.

Vibration, functional

Shock

Salt mist

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D-U200-W

Technical specifications
Environmental characteristics
Damp heat EC60068-2-30, Test method Db, variant 1, with the following details. Step 1 The relays were placed in the humidity chamber in a manner which simulated its normal service position. Initially, the chamber temperature was at standard ambient with uncontrolled humidity. The chamber was programmed to perform the following 24-hour temperature humidity cycle: Step 2 The internal chamber temperature was gradually raised to +55C and the relative humidity to 95% over a period of 3 hours. Step 3 The conditions of a 55C and 95% R.H. were maintained for 9 hours. Step 4 The chamber conditions were uniformly reduced from +55C and 95% R.H. to +25C and 95% R.H. over a period of 1.5 hours. Step 5 The conditions of +25C and 95% R.H. were maintained for 10.5 hours. Step 6 Steps 2, 3, 4 and 5 were repeated for six (6) cycles (144 hours) with the relays non-operating. Step 7 The relays were then removed from the chamber and visually examined for corrosion and external physical damage. The relays were then subjected to the Dielectric withstanding voltage test and contact resistance test. NF F16-101/102, TS 45545-2 fire and smoke material selection and application for electrical equipment. IEC 60529 ; IP40

Fire and smoke

Protection level

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D-U200-W

Technical specifications
Safety characteristics
Weld No Transfer The D-U200-Wxxx relay with weld-no-transfer contacts complies to the standards NF F62002 (12.3.10) and EN50205 Type A. With the option weld-no-transfer a normally open contact will not close if a normally closed contact fails to open and the relay is energized. Also, a normally closed contact will not close if a normally open contact fails to open and the relay is de-energized. Testing according to NF F62002 12.3.10: - with one NC-contact kept closed, none of the NO-contacts may close a test circuit of 10mA@220V50Hz when the coil is energized with 150% of the maximum specified coil voltage (=150% * 125%Unom=188%Unom). The other NCcontacts may open. - with one NO-contact kept closed, none of the NC-contacts may close a test circuit of 10mA@220V50Hz when the coil is de-energized. The other NO-contacts may open. Testing according to EN50205: - if one NC-contact fails to open, all NO-contacts must maintain a contact gap 0,5mm when the coil is energized with the maximum energizing quantity which can occur under worst case conditions, namely: * maximum coil voltage * minimum ambient temperature * minimum coil resistance - if one NO-contact fails to open, all NC-contacts must maintain a contact gap 0,5mm when the coil is de-energized. - all tests must be performed under worst case conditions - above requirements apply throughout the specified endurance and under reasonable foreseeable single failure conditions. - failure mode and effect analysis (FMEA) has been performed to verify the design.

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D-U200-W

Technical specifications
Electrical life expectancy
Due to the safety nature of the D-U200-W relays, please contact Mors Smitt with detailed contact load data. With this information, Mors Smitt can provide a correct advice in line with your specific application. Required contact data: - Voltage - Current - Inductance of load - Kind of suppression used on load - Required number of operations - Switching frequency

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D-U200-W
Sockets
Mounting possibilities/sockets

V3

V22 BR

V23

V23BR

V24

V25

V26

V29

V31

V32

V33

Surface/wall mounting
338.000.302 338.000.580 338.300.100 338.000.610 V22BR V23 V24 V29 Screw socket, wall mount, front connection (9 mm terminals) Screw socket, wall mount, front connection (7,5 mm terminals) Faston connection socket, wall mount, front connection (6,3 mm or 2 x 2,8 mm) Cage clamp socket, wall mount, front dual connection (2,5 mm2)

Rail mounting
338.000.580 338.000.402 338.300.200 338.000.610 V23 V23BR V25 V29 Screw socket, rail mount, front connection (7,5 mm terminals) Screw socket, rail mount, front connection (9 mm terminals) Faston connection socket, rail mount, front connection (6,3 mm or 2 x 2,8 mm) Cage clamp socket, rail mount, front dual connection (2,5 mm2)

Panel/flush mounting
338.100.100 328.400.100 338.000.560 338.000.570 V3 V26 V31 V33 Solder tag socket, panel mount, rear connection Crimp contact socket, panel mount, rear connection, A260 crimp contact Faston connection socket, rear dual connection (5 mm) Cage clamp socket, flush mount, rear dual connection (2,5 mm2)

PCB mounting
338.000.561 V32 PCB-soldering socket For more details see datasheets of the sockets
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D-U200-W
Keying
Mechanical keying relay to socket (optional)

Function: To prevent wrong installation To prevent damage to equipment To prevent unsafe situations Using keyed relays and sockets prevents a relay being inserted in a wrong socket. For example it prevents that a 24 VDC relay is put in a 110 VDC circuit. Positive discrimination is possible per different funtion, coil voltage, timing, monitoring, safety and non-safety. The D-Series relay-socket keying option gives 8 x 8 = 64 possibilities. Upon ordering the customer simply indicates the need for the optional keying. Mors Smitt will assign a code to the relay and fix the pins into the relay. The sockets are supplied with loose key receptacles. Inserting the keys into the socket is very simple and self explaining. Top view socket Bottom view relay

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A104 key receptacle

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Left
8 Pos itio
8 Pos itio

8 Pos itio

8 Pos itio

laceme nt of p ns
B C D

E H F

Example keying position G-Z on socket

All weld-no-transfer relays have 4 pins not placed (of the 14 pins in total). This makes it possible to key the socket to prevent placement of non weld-no-transfer relays. Pin occupation is shown at page 2 in the diagram. Pin occupation is depending on the selected contact configuration.

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A104 key receptacle

3
F

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G H D C B

X Y Z

10

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V U T

keying pin

keying pin

13

Right
laceme nt of p ns
T U V

Left
laceme nt of p ns
H G F

Right
n

fp so

laceme
Y

nt
ss po
ible

ss po
ible

ss po

ss po

ible

ible

W Z X

A B C D

W T U V

Example keying position G-Z on relay

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D-U200-W
Installation

Instructions
Installation, operation & maintenance
Before installation or working on the relay: disconnect the power supply first! Install socket and connect wiring according to the terminal identification. Plug relay into the socket ensuring there is no gap between the bottom of relay and the socket. Reverse installation into the socket is not possible due to the mechanical blocking snap-lock feature. Check to ensure that the coil connection polarity is not reversed. Relays can be mounted tightly together to save space. When surface/rail mounting is used, it is recommended to mount the socket in the direction of the UP arrow. (symbol on socket) Warning! ! - Never use silicon spray in the proximity of the relays. - Do not use the relay in the presense of flammable gas as the arc generated from switching could cause ignition. - To remove relays from the socket, employ up and down lever movements. Sideway movement may cause damage to the coil wires.

Operation
Never use the relay outside its specifications. After installation always apply the rated voltage to the coil to check correct operation. Long term storage may corrode the silver on the relay pins. When plugging the relay into the socket, the female bifurcated or trifurcated receivers will automatically cut through the corrosion on the pins and guarantee a reliable connection. Before actual use of relays, it is advised to switch the load several times with the contacts. The contacts will both be electrically and mechanically cleaned due to the positive wiping action. Sometimes a contact can build up increased contact resistance (< 15mW when new). When using silver contacts one can clean the contact by switching a contact load a few times using >24Vdc & ~ 2A. Increased contact resistance is not always problematic, as it depends on circuit conditions. Condensation in the relay is possible when the coil is energised (warm) and the outside, environmental temperature is cold. This is a normal phenomenon and will not affect the function of the relay. Materials in the relay have no hygroscopic properties.

Maintenance
Correct operation of the relay can easily be checked as the transparent cover provides good visibility of the moving contacts. If the relay does not seem to operate correctly, check for presence of the appropriate coil voltage and polarity using a suitable multimeter. If a LED is fitted, voltage to the coil presence should be indicated. If coil voltage is present, but the relay does not operate, a short circuit of the suppression diode is possible (this may be due to the coil connection having been reversed). If the relay doesnt work after inspection, replace the relay unit with a similar model. Do not attempt to open the relay cover or try to repair. Contacts are calibrated and in balance, touching can affect proper operation. Also resoldering may affect correct operation. Since 2009 relays have tamper proof seals fitted and once broken, warranty is void. Most relay defects are caused by installation faults such as overvoltage, spikes/transients, high/short current far exceeding the relay specifications. When returning the relays for investigation, please provide all information on the RMA form. Send defective relays back to the manufacturer for repair or replacement. Normal wear and tear or external causes are excluded from warranty.
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D-U200-W
D-U2
1. Relay model

Ordering Scheme
01
2. Coil voltage

W013

code AS

3. Options 4. Contact config. 5. Keying

This example represents a D-U201-W013 code AS. Description: D-U200 series relay, Unom: 24 VDC, Weld no transfer, 1 NC / 3 NO, keying AS.

1. Relay model

3. Options
C = Low temp (-50oC) - Max contact current 8 A E = Gold plated contacts K = Special dust protection L = LED coil indicator M = AgSnO2 contacts, highly resistant to welding N = No magnetic arc blow-out P = Polarisation diode Q = Double zener diode T = Push-to-test-button X2 = Coil for both DC and AC Y = Double make/ double break (Y = -50oC) Z = No diode

D-U2
2. Coil Voltages
01 = 24 VDC 02 = 48 VDC 03 = 72 VDC 04 = 110 VDC 07 = 36 VDC

4. Contact configuration
W013 = Weld no transfer, 1 NC / 3 NO W022 = Weld no tranafer, 2 NC / 2 NO W031 = Weld no transfer, 3 NC / 1 NO

5. Keying (optional)*
Standard, silver contacts Code AS 24 VDC Code AY 36 VDC Code AT 48 VDC Code AU 72 VDC Code AV 110 VDC Option E, gold contacts Code DT 24 VDC Code FV 36 VDC Code HU 48 VDC Code AZ 72 VDC Code HV 110 VDC D-U201 code AS D-U207 code AY D-U202 code AT D-U203 code AU D-U204 code AV D-U201-E code DT D-U207-E code FV D-U202-E code HU D-U203-E code AZ D-U204-E code HV Top view socket
up

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Bottom view relay

Option M, silver tin oxide contacts Code GT 24 VDC D-U201-M code GT Code HT 36 VDC D-U207-M code HT Code GU 48 VDC D-U202-M code GU Code GV 72 VDC D-U203-M code GV Code GW 110 VDC D-U204-M code GW Note: For option W keying is also included in Wxxx option.
* Obligatory for applications in France

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Australian Distributor

Relay Monitoring Systems Pty Ltd 6 Anzed Court Mulgrave, Victoria, 3170, Australia Phone: +61 3 8544 1200 Fax: +61 3 8544 1201 Email: rms@rmspl.com.au Web: www.rmspl.com.au