1.

INTRODUCTION
A relay is an electrically operated switch. Many relays use an electromagnet to mechanically
operate a switch, but other operating principles are also used, such as a solid-state relays.
Relays are used where it is necessary to control a circuit by a separate low power signal, or
where several circuits must be controlled by one signal. The first relay was used in long
distance telegraph circuit as amplifier: they repeated the signal coming in form one circuit
and re-transmitted it to another circuit. Relays were used extensively in the telephone
exchanges and early computers to perform logical operations.

A type of relay that can handle the high power required to directly control an electric motor
or other loads is called a contractor. Solid-state relays control power circuits with no moving
parts, insted using a semiconductor device to perform switching. Relays with calibrated
operating characteristics and sometimes multiple operating coils are used to protect electrical
circuits from overload or fault; in modern electric power system these functions are
performed by digital instruments still called ”protective relays ”.

Relays are the primary protection as well as switching devices in most of the control
processes or equipment regardless of whether they are electronic or electromechanical. All
the relays respo0nd to one or more electrical quantities like voltage or current such that they
open or close the contact or circuits. A relay is a switching device as it works to isolate or
change the state of electric current from one state to other. These are found in all sorts of
devices. Relays allow one circuit to switch over to a second circuit that can be completely
separated from the first. There is no electrical connection inside the relay between the two
circuits-the link is magnetic and mechanical only.

Fig-1.a Fig- 1.b

2. HISTORY
In 1833, Carl Friedrich Gauss and Wilhelm Weber developed an electromagnet relay.

American scientist Joseph Henry is often claimed to have invented a relay in 1835 in order to
improve his version of the electrical telegraph, dev eloped earlier in 1831.

It claimed that the English inventor Edward Davy “certainly invented the electrical relay” in
his electric telegraph c.1835.

A simple device, which is now called a relay, was included in the original 1840 telegraph
patent of Samuel Morse. The mechanism described acted as a digital amplifier, repeating the
telegraph signal, and thus allowing signals to be propagated as for as desired.

The word relay appears in the context of electromagnetic operations from 1860.

3. HOW IT WORKS
Basically a relay consists of an electromagnet coil, an armature, a spring and a series of
electrical contacts. The electromagnet coil gets power through a switch or a relay driver and
causes the armature to get connected such that the load gets the power supply. The armature
movement is caused using spring. Thus, the relay consists of two separate electrical circuits
that are connected to each other only through a magnetic connection, and the relay is
controlled by controlling the switching of the electromagnet.

The contacts are usually common (COM)-normally open(NO) and normally closed(NC).The
normally closed contact is connected to the common contact if power is not applied to the
coil. The normally open contact is opened if power is not applied to the coil. When the coil is
energized, the common contact is connected to the normally open contact, and the normally
closed contact is left floating. The double-pole4 versions are same as the single-pole version
except when the two switches open and close together.
 Fig -3: Working of relay

4. CLASSIFICATION OF RELAYS
Classifications or the types of relays depend on the function for which they are used. Some of
the categories include protective, reclosing, regulating, auxiliary and monitoring relays.
Protective relays are continuously monitor these parameters: voltage, current and power; and,
if these parameter violate from the set limits, the protective relays generate an alarm or isolate
that particular circuit. These types of relays are used to protect equipments like motor,
generators and transformers and so on. Some of these are induction type cover current relays,
distance relays, differential relays, etc.

Reclosing relays are used to convert various components and devices within the system
network, such as synchronizing process, and to restore various devices soon after any
electrical fault vanishes, and also to connect transformers and feeders to a line network.
Regulating relays are the switches that contact such that a voltage boots up as in the case of
tap-changing transformers.

Auxiliary contacts are used, in circuit breakers and other protective equipments for contact
multiplication. Monitoring relays monitor a system conditions such as direction of power and
accordingly generates an alarm. These relays are also calle3das directional relays.

Depending on the operating principle and structural features, relays are of different types:

 Electromagnetic relays
 Thermal relays
 Power varied relays
 Multi-dimension relays and so on.

5. ELECROMAGNETIC RELAYS
The relays are constructed from electrical, mechanical and magnetic components, and process
operating coil and mechanical contacts. Therefore, when a coil gets activate4d by a power
supply source, these mechanical contacts get opened or closed. The type of supply can be AC
or DC.
 Fig- 5: Electromagnetic relay

Both AC and DC relays work on the same principle as that of electromagnetic induction, but
the construction is somewhat differential and also depends on the application for which these
relays are selected. DC relays are employed with a freewheeling diode to de-energize the coil,
and the AC relays use laminated cores to prevent eddy current loss.

The very interesting aspect of an AC is that, for every half cycle, the direction of the current
supply changes; therefore, for every cycle, the coil losses its magnetism since the zero current
in every half cycle makes that the relay continuously make and break the circuit. So-to
prevent this-additionaly one shaded coil or other electronic circuit is placed in the AC relay to
provide magnetism in the zero current position.

5.1 ATTRACTION TYPE ELECTROMAGNETIC RELAYS

These relays can work with both AC and DC supply and attract a metal bar or a piece of
metal when power is supplied to the coil. This can be a plunger being drawn towards the
solenoid or an armature being attracted towards the poles of an electromagnet, as shown in
the figure.. These4 relays don’t have any time delays, so these are used for instantaneous
operation. These can be typed like:

a)Attracted Armature Relay

b) Solenoid Type Relay

c)Balanced Beam Relay

Fig- 5.1: Attractive type electromagnetic relay

5.2 INDUCTION TYPE RELAYS
These are used as protective relay systems. The actuating of contacts, movement is developed
by a moving conductor that may be a disc or a cup, through the intersection of
electromagnetic fluxes due to fault currents.

These are of several types like:

a) Shaded Pole Type Relays.

b) Watt- hour Meter Type Relays.

c) Induction Cup Structure Relays.

Shaded pole relays consist of aluminium disc, which is pivoted such that it freely rotates in
the air gap of an electromagnet. Shaded ring or copper ring is surrounded on one half of each
pole. The induced currents in this shaded ring produce another flux called as shaded flux,
which lags behind the flux produced by the unshaded pole by same angle. The phase
difference between these two fluxes produces necessary torque to rotate the disc.

Fig- 5.2.a: Shaded Pole Type Relay

The watt-hour structure type relay works as an electromagnetic induction type watt-hour a
meter so named, after it. It consists of two magnets: upper and lower electromagnets and
aluminium disc, which is pivoted such that it rotates freely between the two electromagnets.
In this relay, the upper magnets consist of two windings: primary and secondary windings,
wherein the primary winding carries the relay current and the secondary winding is connected
to the lower magnet. This primary current induces EMF in the secondary winding, so it
produces a flux that lags behind the main flux by some angle. The phase difference of these
fluxes produces toque on the disc, whose magnitude is proportional to the product of these
two fluxes multiplied by the sine angle between these two fluxes

Fig- 5.2.b: Watt-hour Meter type relay

The induction cup structure relay works on similar principle of an induction disc relay.
This relay can be four pole or eight pole depending on the number of windings
accommodated. Due to the replacement of these disc with an aluminium cup, the inertia of
the rotating system is significantly reduced. In this type of relay, the rotating magnetic field is
produced by one pair of poles inducing a current in the aluminium cup.

In this way, the cup movement or torque is produced by the intersection of fields produced by
the two pair of poles that have lagged one another with some angle. In the normal operating
conditions, the cup remains standstill, but, in case of any fault, a very high current in the coil
causes to move the cup so that the circuit gets isolated from the power supply.

Fig- 5.2.c: Induction Cup Type Relay

5.3 LATCHING AND NON-LATCHING RELAYS

5.3.1 Non-Latching relays

This type of relays is initially at a normally closed (NC) position which is maintained by the
force of a spring of magnet if no current flows through the coil. If a current flowing through
the relay coil, the normally open (NO) contacts is operated by the magnetic field of the coil
and when the current stops, it reverts back to the NC position.

5.3.2 Latching relays

These relays are used in application where there is a need to limit power dissipation and
consumption. These latching relays consist of 1 or 2 coils and have no default position., but
when current stops flowing remain in their last position. Once these relays are actuated they
didn’t require any power to maintain their position, but their reset position is based on the
control circuitry. The direction of current flows in one coil relay determines the position of
the relay, whereas particular coil current flow determines the position of armature in 2-coil
latching relay.
6. SOLID STATE OR ELECTRONIC RELAYS
Solid state uses solid state components to perform the switching operations with one or more
semiconductor switching devices like a power transistor, thyristor and TRIAC without
moving any parts. Since control energy required is much lower, compared to the output
power to be controlled by this relay, which may result the power gain higher compared to the
electromagnetic relays. These relays are of different types:

a) Reed relay coupled SSR

b) Transformer-coupled SSR

c) Photo- coupled SSR and so on.

6.1 Reed Relay Coupled SSR

Reed relay consist of a pair of magnetic strips (also called as reed) that is sealed within a
glass tube. This reed acts as both an armature and a contact blade. The magnetic field applied
to the coil is wrapped around this tube that makes these reeds move so that switching
operations is performed.

Based on the dimension, relays are differentiated as micro, miniature, sub-miniature and
miniature relays. Also, based on the construction, these relays are classified as hermetic,
sealed and open type relays. Furthermore, depending on the load operating on the operating
range, relays are of micro, low, intermediate and high power types.

Fig-6.1.a: Reed Relay Coupled SSR

6.2 Transformer Coupled SSRs
In this type of relay, a control signal is applied to the primary of the low power, small
transformer through AC or DC converter if the supply is DC, otherwise we can connect
directly if it is AC. The secondary excitation is used to trigger the thyristor switch with or
without rectification and amplification depending on the type of circuit. The design of the
transformer decides the degree of isolation between the input and output.

Fig-6.2: Transformer Coupled SSRs

6.3 Photo-coupled SSRs

The figure shows a photo- coupled SSRs where the control signal is applied by LED and it is
detected by a photo- sensitive semiconductor device. The output from this photo detector is
used to trigger the gate of TRIAC or SCR that switches the load. The electric isolation
between the input and output is high due to optical coupling between them as compared to the
magnetic one.

Fig- 6.3: Photo Coupled SSRs

6.4 Direct Control AC SSR Relays
In this relay, operating load circuit AC power is also given to the control circuit to trigger the
TRIAC. This is a simple design and less expensive, but it doesn’t provide any isolation
between the control and power circuit.

Fig- 6.4: Direct Control AC SSRs Relays

6.5 Direct Control DC SSR Relays

As similar to the above one, in this type of the relay also the control circuit is energized with
the same DC power used in the load circuit. This dc power is utilize to bias the transistor so
that it is conducted to pass the current to the load. This is also less expensive and simplest
circuit than the more sophisticated designs, but without isolation between the load and the
control circuit is the biggest problem or disadvantages.

Fig- 6.5: Direct Control DC SSR Relay

7. HIGH VOLTAGE RELAYS
These relays are quite similar in function to that of lo0w voltage relays, but the major
difference is the contacts which are designed to operate at high voltages. Therefore, a high
insulation is provided between the contacts, between contacts and earth, and between the
activator and contacts. This relay contacts are typically placed in a different medium enclosed
by ceramic or glass to prevent arcing at the time of switching. Generally, two kinds of
mediums; vacuums and high-pressure gas are used in these relays as contacts medium.

7.1 Vacuum Filled High Voltage Relays

As the characteristics like high-voltage breakdown, fast-recovery rate and an absolutely non-
reactive and inert environment, vacuum is the ideal dielectric that contains a very few gas
molecules. The dielectric strength of vacuum is 10000V per 0.1mm in vacuum and also due
to no air, the contacts become oxidation free. These relays have stable and low-contact
resistance, so these are widely employed in Radio Frequency (RF) applications.

Fig - 7.1: Vacuum Filled High Voltage Relays

The figure shows the components in vacuum relay. This type of relay permits the use of low
mass actuators with the small movement, which is enough to operate it. When the load is
switched, an arc is formed in between the contacts. Due to the presence of the vacuum, this
arc no longer stays, but breakdowns within a moment.
7.2 Gas Filled High Voltage Relays
These relays also provide dielectric strength and avoids the oxidation. Therefore, these are
ideal for high inrush make and capacitive discharge loads such as cable test equipment, ESD
test equipment, heart defibrillators, etc. In these relays, a mixture of SF6, sulphur hexa
fluoride and nitrogen is used as gas medium. But arc is formed in this relay when the contacts
get opened and sustained for longer durations, compared to the vacuum relays.

Fig- 7.2.a Fig – 7.2.b

Fig – 7.2: Gas Filled High Voltage Relay

8. Time Delay Relays

The time delay relays are used for performing time-delayed switching operations such as
starting, protecting and controlling circuits applications. This relay consists of a relay
mechanism with a control circuit wherein the control circuits is made with solid state
components and timing circuits so that a control operation with a pre-defined-timing range is
performed. This time-delay function includes on delay, off delay, repeat cycle, one shot, re-
triggerable one shot, pulse generator, on or off delays, etc. A special type of such relay is a
star-delta wherein within a certain time period it changes the terminal connection.

These are of different types like:

a)Electromagnetic Time Relay

b )Capacitor Time Relay

c) Electronic Relay

d) Hydraulic and pneumatic Relays

e) Microprocessor Based Time Relay

f ) Accelerated Time Relays

Along with the above types, time delay relays can also be differentiated depending on
normally open or normally closed contacts with the time delay in the direction of closing or
opening. These are of different types like normally –open timed-closed contact (NOTC),
normally-open timed-open (NOTO), normally-closed timed-open (NCTCO) and normally –
closed timed-closed (NCTC) contact type relays.

Depending on the function, these time relays can also be triggered or initiated either with the
application of a trigger or input voltage. These initiated signals can be controlled-switch-like
push buttons, limit switch, float switch, etc ,or simply a power trigger with voltage excitation.

Fig – 8.a Fig – 8.b

Fig – 8: Time Delay Relay

9. Thermal Relay
These relays are based on the effects of heat, which means-the rise in the ambient
temperature from the limit, directs the contacts to switch from one position to another. These
are mainly used in protecting motor and other inductive loads against single phasing,
overload and unbalanced voltages. This relay consist of bimetallic elements like temperature
sensors as well as control elements. Thermal overload relays are the best examples of these
relays. These are of different types like:

a) Bimetallic Thermal Relay

b) Solid State Thermal Relay

c) Melting Alloy Relays

d) Temperature Controlled Thermal Relays

9.1 Bimetallic Thermal Relays

When a bimetallic strip heats up, it expands or bends due to the inequality of linear expansion
of two dissimilar metals. For any reason, if the circuit draws heavy or excessive currents, this
in turn causes to increase the temperature of winding or conductor so this bimetallic strip also
gets expanded, and then finally the current contacts become open. These relays can be used to
operate either in automatic or manual modes.

Fig- 9.1: Bimetallic Thermal Relay

9.2 Solid State Thermal Relay
This relay is built with solid state electronic components. It continuously monitors the
starting and running currents correspondingly calculate the average motor or load
temperature. If the limits of the temperature exceed, then it trips the load.

Fig- 9.2: solid State Thermal Relay

9.3 Melting Alloy Relays

This relays consist of a eutectic alloy, heater coil and triggering mechanism. This alloy with
ratchet alloy changes from solid to liquid state at fixed temperature. This alloy with ratchet
wheels acts as tripping device to open the control circuits contacts. This relays allows the
motor current to pass through the heater coil; thus, under overload condition, this coil heats
up the eutectic alloy and melts it. This in turn causes the freeing, and turns the ratchet wheel
so that the tripping mechanism is activated.

Fig- 9.3: Melting Alloy Relay

9.4 Temperature Control Thermal Relays
These relays are used in motor winding protection and use temperature sensors like
therminstors and Resistance Temperature Detector (RTDs). These sensors are embedded in
the motor winding which detects the temperature and threshold circuit in its open-relay
contacts.

Furthermore, these thermal relays can be Oil Temperature trip (OT), Windings Temperature
(WT) trip and Bearing Temperature trip types.

Relays are also available with different pin configurations like 3-pin, 4-pin and 5-pin relays.
The ways in which these relays ate operated is shown in figure. Switching contacts can be
SPST, SPDT, DPST, and DPDT types. Some of the relays are normally open(NO) type and
the other are normally closed(NC) types.

10. Applications of Relays

 Control a high voltage circuit with a low signal, as in some type of modems or audio
amplifiers.
 Control a high current circuit with a low current signal, as in the starter solenoid or an
automobile.
 Detect and isolate faults on transmission and distribution lines by opening and closing
the circuit breakers.
 Time delay function. Relays can be modified to delay opening or delay closing set of
contacts. A very-short delay uses a copper disk between the armature and moving
blade assembly.
 Typical applications of relays include computer interfaces, telecommunication
systems, traffic control, automotive electrical system, home appliances, lighting
control systems, electric motor controllers, tools and machines, air conditioning and
heating systems and so on.

11. Relay application considerations

Selection of an appropriate relay for a particular operation requires evaluation of many
different factors.

 Number and type of contacts – normally open, normally closed.

 Contact sequence-“Make before break” or “break before make”. For example, the old
style telephone exchange requires Make before break so that the connection didn’t get
dropped while dialling the number.
 Contact current rating – small relays switch a few amperes, large contractors are rated
for up to 3000 amperes, alternating or direct current.
  Contact voltage rating – typical control relays rated 300VAC or 600VAC, automotive
types of 50VDC, special high voltage relays to about 15,000V.
 Operating lifetime, useful life – the numbers of times the relay can br expected to
operate reliability. There is both a mechanical life and a contact life. The contact life
is affected by the type of load switched. Breaking load current causes undesired
arching between the contacts, eventually leading to contacts that weld shut or contacts
that fail due erosion by the arc.
 Coil voltage – machine tool relays usually 24VDC, 120 or 250VDC, relays for
switchgear may have 125 V or 250 VDC coils.
 Coil current – Minimum current required for reliable operation and minimum holding
current, as well as, effects the power dissipation on coil temperature, at various duty
cycles. “Sensitive ” relays operate on few milli amperes.
 Package/enclosure – open, touch- safe, double-voltage for isolation between circuits,
explosion proof, outdoor, oil and splash resistance, washable for printed circuit board
assembly.
 Operating environment– Minimum and maximum operating temperature and other
environment considerations such as effects of humidity and salt.
 Assembly – Some relays feature a sticker that keeps the enclosure sealed to allow
PCB post soldering cleaning, which is removed once assembly is complete.
 Mounting – sockets, plug board, rail mount, panel mount, through-panel
mount,enclosure for mounting on walls or equipment.
 Switching time – where high speed is required
 “Dry” contacts – when switching very low level signal, special contacts materials may
be needed such as gold-plated contacts.
 Contact protection – suppress arching in very inductive circuits.
 Coil protection – suppress the surge voltage produced when switching the coil current
.
 Isolation between coil contacts.
 Aerospace or radiation-resist testing, special quality assurance.
 Expected mechanical loads due to acceleration – some relays used in aerospace
applications are designed to function in shock of 50g or more.
 Size – smaller relays often resist mechanical vibration and shock better than larger
relays, because of the lower inertia of the moving parts and the higher natural
frequencies of smaller parts. Larger relays often handle higher voltage and current
than the smaller relays.
 Accessories such as timers, auxiliary contacts, pilot lamps and testing buttons.
 Regulatory approvals.
 Stray magnetic linkage between coils of adjacent relays on a printed circuit board.

There are many considerations involved in the correct selection of the control relay for a
particular application. These considerations include factors such as speed of operation,
sensitivity, and hysteresis.
Although typical control relays operate in the 5 ms to 20 ms range, relays with switching as
fast as 100 us are available. Reed relays which are actuated by low currents and switch fast
are suitable for controlling currents.

Consequently, for relays used to control inductive loads, we must specify the maximum
current that may flow through the relay contacts when it actuates, the make rating ; the
continuous rating and the break rating. The make ratings may be several times larger than the
continuous rating, which is itself larger than the break rating.

12. Derating factors

Type of load % of rated value
Resistance 75

Inductance 35

Motor 20

Filament 10

Capacitive 75

Control relays should not be operated above rated temperature of resulting increased
degradation and fatigue. Common practice is to derate 20 degree Celsius from the maximum
rated temperature limit. Relays operating at rated load are affected by their environment. Oil
vapour may greatly decrease the contact life, and dust or dirt may cause the contacts to burn
before the end of normal operating life. Control relay life cycle varies from 50,000 to over
one million cycles depending on the electrical load on the contacts, duty cycle, application,
and the extent to which the relay is derated. When a control relay is operating at its derated
value, it is controlling a smaller value of current than its maximum make and break ratings.
This is often done to extend the operating life of a control relay. The table lists the relay
derating factors for typical industrial control application.
13. Protective Relays
For protection of the electrical apparatus and transmission lines, electromechanical relays
with accurate operating characteristics were used to detect overload, short circuit, and other
faults.

While many such relays remain in use, digital protective relays now provide equivalent and
more complex protective functions.

14. Railway signalling

Railway signalling relays are large considering the mostly small voltages and currents that
they switch. Contacts are widely spaced to prevent flashover and short circuits over a life
time that may exceed fifty years. BR930 series plug-in relays are widely used on railway
following British practice. These are 120mm high, 180mm deep and 56mm wide and weight
about 1400g, can have up to 16 separate contacts, for example, 12 make and 4 break contacts.
Many of these relays come in 12V, 24V and 50V versions.

The BR Q-type relays are available in a number of different configurations:

 QN1 Neutral
 QL1 Latched
 QNA1 AC-immune
 QBA1 Biased AC-immune
 QNN1 Twin Neutral (2*4-4) or (2*6-2)
 QBCA1 Contactor for high current applications such as point motors. Also DC biased
and AC biased immune.
 QTD4- slow to release timer
 QTD5 – slow to pick up timer

Since rail signal circuit must be highly reliable, special techniques are used to detect and
prevent failures in the relay system. To protect against false feeds, double switching relay
contacts are often used on both the positive and negative side of a circuit, so that two false
feeds are needed to cause a false signal. Not all relay circuits can be proved so there is
reliance on construction features such as carbon to silver contacts to resist lighting induced
contact welding and to provide AC immunity.

Opto-isolators are also used in some instance with railway signalling, especially where only a
signal contact is to be switched.

Signalling relays, typical circuits, drawing symbols, abbreviations & nomenclature, etc, come
in a number of schools, including the United states, France, Germany and united kingdom.
Reference
www.google.com

www.wikipedia.com

www.circuitglobe.com

www.stduymafia.org
 Contents
1. Introduction 1

2. History 2

3. How it works 2

4. Classification Of Relay 3

5. Electromagnetic Relay 3

5.1 Attraction type Relay 4

5.2 Induction type Relay 5

5.3 Latching and Non-latching Relay 7

6. Solid state or Electronic Relay 8

6.1 Reed Relay Coupled SSR 8

6.2 Transformer Coupled SSRs 9

6.3 Photo Coupled SSRs 9

6.4 Direct Control AC SSRs Relay 10

6.5 Direct Control DC SSRs Relay 10

7. High Voltage Relay 11

7.1 Vacuum Filled High Voltage Relay 11

7.2 Gas Filled High Voltage Relay 12

8. Time Delay Relay 12

9. Thermal Relay 13

9.1 Bimetallic Thermal Relay 14

9.2 Solid State Thermal Relay 15

9.3 Melting Alloy Relay 15

9.4 Temperature Control Thermal Relay 16

10. Application Of Relay 16

11. Relay Application Consideration 17

12. Derating Factors 18

13. Protective Relays 19