Week 9 of FYP 1

Date: 11/11/2013 – 14/11/2013 (Monday to Thursday)

Title: Research and Findings (Relay)

Introduction

A relay is an electrically operated switch. Current flowing through the coil of the relay creates a magnetic field which attracts a lever and changes the switch contacts. The coil current can be on or off so relays have two switch positions and most have double throw (changeover) switch contacts.

Relays allow one circuit to switch a second circuit which can be completely separate from the first. For example a low voltage battery circuit can use a relay to switch a 230V AC mains circuit. There is no electrical connection inside the relay between the two circuits; the link is magnetic and mechanical.

The coil of a relay passes a relatively large current, typically 30mA for a 12V relay, but it can be as much as 100mA for relays designed to operate from lower voltages. Most ICs (chips) cannot provide this current and a transistor is usually used to amplify the small IC current to the larger value required for the relay coil. The maximum output current for the popular 555 timer IC is 200mA so these devices can supply relay coils directly without amplification.

Relays are usually SPDT or DPDT but they can have many more sets of switch contacts, for example relays with 4 sets of changeover contacts are readily available. Most relays are designed for PCB mounting but we can solder wires directly to the pins providing us to avoid melting the plastic case of the relay.

The supplier's catalogue should show you the relay's connections. The coil will be obvious and it may be connected either way round. Relay coils produce brief high voltage 'spikes' when they are switched off and this can destroy transistors and ICs in the circuit. To prevent damage we must connect a protection diode across the relay coil.

The relay's switch connections are usually labelled COM, NC and NO:

COM = Common, always connect to this; it is the moving part of the switch.

NC = Normally Closed, COM is connected to this when the relay coil is off.

NO = Normally Open, COM is connected to this when the relay coil is on.

Relay Circuit

Selection of the Relays

There are several features that need to be considered when choosing a relay:

Physical size and pin arrangement

- If we are choosing a relay for an existing PCB we will need to ensure that its dimensions and pin arrangement are suitable. We should find this information in the supplier's catalogue.

Coil voltage

- The relay's coil voltage rating and resistance must suit the circuit powering the relay coil. Many relays have a coil rated for a 12V supply but 5V and 24V relays are also readily available. Some relays operate perfectly well with a supply voltage which is a little lower than their rated value.

Coil resistance

- The circuit must be able to supply the current required by the relay coil. We can use Ohm's law to calculate the current:

Relay coil current  = supply voltage/coil resistance

For example: A 12V supply relay with a coil resistance of 400ohm passes a current of 30mA. This is OK for a 555 timer IC (maximum output current 200mA), but it is too much for most ICs and they will require a transistor to amplify the current.

Switch ratings (voltage and current)

- The relay's switch contacts must be suitable for the circuit they are to control. You will need to check the voltage and current ratings. Note that the voltage rating is usually higher for AC, for example: "5A at 24V DC or 125V AC".

Protection diodes for relays

Protection diode for a relay Transistors and ICs must be protected from the brief high voltage produced when a relay coil is switched off. The diagram shows how a signal diode (ex. 1N4148) is connected 'backwards' across the relay coil to provide this protection.

Current flowing through a relay coil creates a magnetic field which collapses suddenly when the current is switched off. The sudden collapse of the magnetic field induces a brief high voltage across the relay coil which is very likely to damage transistors and ICs. The protection diode allows the induced voltage to drive a brief current through the coil (and diode) so the magnetic field dies away quickly rather than instantly. This prevents the induced voltage becoming high enough to cause damage to transistors and ICs.

Protection Diode For Relay