Relays-types-operations-specification-symbols

Relay: A relay is a device which opens or closes an auxiliary circuit under predetermined conditions
in the main circuit. Relays are extensively used in electronics, electrical engineering and many other
fields. There are relays that are sensitive to conditions of voltage, current, temperature, frequency
or some combination of these conditions. Relays are also classified according to their main operating
force as stated under.

– Electromagnetic relays

– Thermal relays

Electromagnetic relay:

: A relay switch assembly is a combination of movable and fixed low-resistance contacts that open or
close a circuit. The fixed contacts are mounted on springs or brackets, which have some flexibility.
The movable contacts are mounted on a spring or a hinged arm that is moved by the electromagnet
in the relay as shown in Fig. 1.

Current sensing relay: A current sensing relay functions whenever the current in the coil reaches an
upper limit.

Under-current relay: Under-current relay is an alarm or protective relay. It is specifically designed to

operate when the current falls below a predetermined value.

Voltage sensing relay: A voltage sensing relay is used where a condition of under-voltage or over-
voltage may cause a damage to the equipment. For example, these types of relays are used in
voltage stabilizers.

Latching relays

Latching relays are capable of maintaining their contacts in the last assumed position without the
maintained current in the coil. These relays hold their contacts in position after power is cut off.
There are two basic kinds of latching relays called mechanical reset and electrical reset.
Mechanical re-set relays:

Mechanical re-set relays have a coil, an armature mechanism, and a mechanical latching device that
locks the armature in the operated position after the coil has been de-energised. Manual tripping of
the locking mechanism, re-sets the relay.

Electrical reset relays:

Reed relays

Reed relays physically look different than other kinds of relays. They consist of essentially
magnetically actuated reed switches, with actuating solenoids or coils.In the reed relay, freedom
from contamination and the limited number of moving parts, avoid many disadvantages of the
conventional electromechanical relays.

In addition to the above, the contact resistance is kept to minimum due to the fact the contact
points are made either with gold or rhodium. Further, these relays need very low power to operate
and can handle a 250 watt solenoid load on their contacts.

There are three types of reed relays namely

– dry-reed relay

– ferreed relay

– mercury wetted contact relay

Dry reed relay:

Fig.3 shows this type of relay. Two opposing reeds are sealed in to a narrow glass tube. The reeds
overlap at their free ends. At the contact area, they are usually plated with gold or rhodium to
produce a low contact resistance. They may have multipole multicontact designs.
Ferreed relay:

The word ferreed denotes a reed relay in which the dry-reed switch is contained with one or more
magnetic members. The magnetisation can be changed by current pulses in associated coils.

As shown in Fig. 4 in the magnetised state the magnetic members supply a field strong enough to
close the contacts. In the other magnetised state, the field is too weak to hold the contacts closed.
An operating pulse through the coil produces the first state. A release pulse produces the second
state. The contacts can break or make within 5 micro-seconds duration.

Mercury wetted contact relay:

As shown in Fig. 5 this relay consists of a glass enclosed reed with its base immersed in a pool of
mercury. When the coil surrounding the capsule is activated, mercury makes the contact between
fixed and movable contacts.

Impulse relay:
The impulse relay shown in Fig. 6 is a special single-coil relay. It has an armature-driven mechanism
that alternatively assumes one of two positions as the coil is pulsed. This mechanism moves the
contact from one position to the other and back again as electrical pulses are received. The relay can
operate on AC or DC power.

Clapper-type armature relay:

The simplest contact arrangement used in armature relays is the break-make or transfer-contact
combination. A clapper-type armature, shown in Fig. 7 opens or closes the contacts. A movable
contact is attached directly to the armature by means of a flexible strip of metal. When the
electromagnet operates, the armature moves this contact, opening and closing the two sets of
contacts.

Thermal relay:

: A thermal relay shown in Fig. 8 is one that operates by changes in temperature. Most of the
bimetallic relays where the bimetallic element changes its shape, in response to changes in
temperature comes under this group. It takes time for the heating element to reach the necessary
temperature and more time to raise the temperature of the bimetallic element. Therefore, thermal
relays are often used as time-delay relays.

Poles and contacts: Relays may operate single or as multi-poles and may open or close specified
contacts. In writing specifications certain abbreviations as stated below are commonly used.
NO indicates the contacts are open in the unoperated position of the relay and they are called as
normally open (NO) contacts.

NC indicates the contacts are closed in the unoperated position of the relay and they are called
normally closed (NC) contacts.

Table 1 given below lists some of the relay contact combinations.

Enclosures and mounts:

Relays are normally enclosed in plastic or metal caps to protect the operating parts against dust and
environment. Relays can be mounted to the circuit direct by plug-in system, PCB mounting or may
be wired separately using screws terminals. These types are shown in Fig. 9.

AC relay:

In an AC relay magnet, the magnetic field continually changes direction. With a 50 Hz supply the
magnetic field passes through zero 100 times per second. At the time of zero field, the armature
starts to release. Although the field quickly builds up in the reverse direction, a noisy chatter can
result.

To eliminate chatter, a shading coil as shown in Fig. 10 is placed near the tip of the magnet pole face.
This shading coil establishes a magnetic field that lags the main magnetic field slightly and aids in
keeping the magnet sealed when the main field passes through zero.
An AC relay should not be used in DC supply. The AC relay when connected to DC supply, will draw
more current in the absence of inductive reactance and result in burning out the coil.

Causes of relay failures:

Causes of relay failures: Relay failures are usually caused by the gradual deterioration of the parts.
This deterioration can be electrical, mechanical or chemical in nature.

In general, when a relay fails, look for the following.

1 Improper control voltage.

2 Dirt, grease or gum on contacts or moving parts.

3 Excessive heating of parts: discolouration or charred insulation on coil or base.

4 Bending of moving parts.

5 Corrosion or deposits on metal parts.

6 Excessive wear on moving parts.

7 Loose connections.

8 Improper spring tension.

9 Improper control pressure.

10 Improper functioning of the time delay device.

Symbols used in relay circuit:

Purpose of overload relays:

The overload relays protect the motor against repeated, excessive momentary surges or normal
overloads existing for long periods, or high currents caused in two phases by the single-phasing
effect. These relays have characteristics which help the relay to open the contactor in 10 seconds if
the motor current is 500 percent of the full load current or in 4 minute

Types of overload relay

There are two types of overload relays. They are :

– magnetic overload relay

– thermal (bimetallic) overload relay.

Magnetic overload relay: The magnetic overload relay coil is connected in series with the motor
circuits. The coil of the magnetic relay must be wound with a wire, large enough in size to pass the
motor current. As these overload relays operate by current intensity and not by heat, they are faster
than bimetal relays.

As shown in Fig. 11, the magnetic coil carries the motor current through terminals 2 and 2' which is
in series with the power circuit. The relay contacts, 95 and 96, are in series with the control circuit.
When a current more than a certain stipulated value, as set by the relay set scale, passes through
the power circuit, the magnetic flux produced by the coil will lift the plunger in an upward direction.

This upward movement makes the plunger tip to push the relay contact lever, and the contact
between terminals 95 and 96 opens. This breaks the no volt coil circuit and the contactor opens the
power circuit to the motor. The relay contacts between terminals 95 and 96 stay open till the rest-
button (not shown in the figure) is pressed.

Bimetallic overload relays:

The tripping of the control circuit in the bimetallic relay results from the difference of expansion of
two dissimilar metals fused together. Movement occurs if one of the metal expands more than the
other when subjected to heat. A U-shaped bimetallic strip is used in the relay as shown in Fig. 12.
The U-shaped strip and a heater element inserted in the centre of the U compartments for avoiding
possible uneven heating due to variations in the mounting location of the heater element.

As shown in Fig 12, under normal conditions, the bimetallic strip pushes the pin against the leaf-
spring tension, and the point contacts 95 and 96 are in a closed position, and hence the no-volt coil
circuit is completed while the motor is running. When a higher current passes through the heater
coil connected to terminals 2 and 2', the heat generated in the coil heats up the bimetal strip which
bends inward.

Hence the pin retracts in the right hand direction and the leaf-spring opens the contact between 95
and 96 to open the contactor. The relay cannot be reset immediately as the heat in the bimetallic
strips require some time for cooling.

Thermal overload relay

Thermal overload is used for motor protection basically thermal overload relay overload relay is an
overcurrent protection of the simplest type. The working principle of thermal overload relay is very
simple thermal overload relay is shown in Fig .13. An adjustment dial located on the unit allows the
ampere trip setting. A manual test button is provided to test the operation of the relay control
contacts.

It is known that diffrent material have diffrent coefficient of thermal expansion. So if two diffrent
metals joined together are heated, then the metal having the greater value of coefficient of thermal
expansion will expand more as compared to the other and this will cause a bend in the bimetallic
strip as shown in Fig 14 a and 14 b. This phenomenon is used in thermal overload relay.
Relay setting: The overload relay unit is the protection centre of the motor starter. Relays come in a
number of ranges. Selection of a relay for a starter depends upon the motor type, rating and duty.

For all direct on-line starters, relays should be set to the actual load current of the motor. This value
should be equal to or lower than the full load current indicated on the nameplate of the motor.
Described here is a simple procedure for setting the relay to the actual load current.

Set the relay to about 80% of the full load current. if it trips, increase the setting to 85% or more till
the realy holds. The realy should never be set at more than the actual current drawn by the motor.
( The actual current drawn by a motor will be less than the full load current in most cases, as motors
may not be loaded to capacity.)

The thermal overload relay shown in Fig-15 is designed for current-depending protection of loads
upto 100A with normal starting (see Functions) against excessive temperature rises due to overload
or phase failure.