DJM30062: INDUSTRIAL ELECTRONIC

CHAPTER 3
RELAY

3.1 INTRODUCTION OF RELAY

The relay is an electromechanical device. The relay offers a simple ON/OFF switching
action and response to a control signal.

Relays are devices that operate as an electrical switch, opening and closing under
electromagnetic conditions. A relay is a simple electro-mechanical switch made up of an
electromagnet and solenoid with a set of contacts. Usually known as control relay. One of oldest
control devices still use in industrial

Figure 3.1(a): Physical (left), Internal structure (middle) and symbol (right) diagram of relay

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.

3.2 RELAY FUNCTION

Two primary functions;

1) Relay can control large current/voltage with small electrical signal because relay coils require
low current/voltage to switch but can energizes large currents or voltages. The structure of
relay itself allows the dc control source at the safe distance from such ac load

2) Isolation of the power used to control the action from the power that must be switch to cause
some action.

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3.3 CONSTRUCTION OF RELAY

Only have two states of operation:

ON and OFF.

Consists four main parts:

1) Solenoid: coil and magnetic core
2) Armature
3) Spring
4) Set of Contacts

Figure 3.3(a): Relay construction

3.4 OPERATION OF RELAY

When electric current passes through a coil, magnetic north and south pole are produced
across the gap separating the coil and armature, acting like an electromagnet.
The magnetic field ‘pull in’ the armature and close the contact NC( Normally close contact), to NO
(Normally open contact) .

When the electrical current stops flowing, the armature return back to normal position
Relay actuated whenever sufficient current intensity produced enough force to overcome spring
tension.

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3.5 RELAY RATINGS & CONFIGURATION

1) The voltage and power type (AC or DC) the coil needs to operate; that is 12Vdc, 24Vdc
and 110Vac.

2) 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 480 VAC
mains circuit.

3) There is no electrical connection inside the relay between the two circuits; the link is
magnetic and mechanical.

4) The coil does not have to work on the same voltage as the voltage being sent over the high
power contacts. There is no need to send high voltage to the small switch.

Figure 3.5(a): Practical application of a relay

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When you purchase relays, you generally have control over several variables:

1. Physical size and pin arrangement

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

2. 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.

3. Coil resistance
The circuit must be able to supply the current required by the relay coil. You can use Ohm's law to
calculate the current:

4. 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".

5. Switch contact arrangement (SPDT, DPDT etc)

Most relays are SPDT or DPDT which are often described as "single pole changeover" (SPCO)
or "double pole changeover" (DPCO).

3.6 RELAY SPECIFICATION REFFERING TO NEMA

National Electrical Manufacturer Association (NEMA), set the voltage level for
relay as stated below:

 The standard voltage for relay used in machine control is 120 volt.
 The coils on electromechanical devices such as relays, contactors and motor
starters are designed so as not to drop out (de-energize) until the voltage
drops to minimum of 85% of the rated voltage.
 The relay coils also will not pick up (energize) until the voltage rises to 85% of
the rated voltage.

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3.7 APPLICATION OF RELAY

Relays are used in the control of fluid power valves and in many machine sequence controls such as
boring, drilling, milling and grinding operations.
Relay also able to:
1. Automatic Control (Only one starter-push button especially in industrial)
2. Changes Action (Normally open and Normally close)
3. Controlling number of component
4. Amplify the current rating
5. Voltage changes
6. Power amplification
7. Memory function

3.8 RELAY CONTROL CIRCUIT

In the figure below, a relatively small switch 24Volt DC source across the coil of the relay located at
the site of the load. When relay coil is energized, the contacts switch the large voltage and current to
the load. The control voltage is DC, and controlled voltage is AC, with both source and grounds
isolates from each other. Contacts are insulated from relay frame and coil as shown is figure.

Figure 3.8: Example of Relay control circuit.

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3.9 PROTECTION CIRCUIT /SNUBBER CIRCUIT FOR RELAY

Needs to suppress the counter e.m.f to a low level.There are 4 types of protection circuit

1. Diode circuit
2. RC circuit
3. Zeners circuit
4. MOV (Metal-oxide varistor) circuit

3.10 BASIC LADDER LOGIC

LADDER LOGIC DIAGRAM DESCRIPTION

OR

AND

SELF-HOLDING/
INTERLOCKING

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3.11 RELAY LADDER DIAGRAM SYMBOL

A "time-delay" relay either waits before actuating after power-up, or waits before de-actuating
after power-down.

A special class of electromechanical relays called time-delay relays provide delayed action,
either upon power-up or power-down, and are commonly denoted in ladder logic diagrams by "TD" or
"TR" designations near the coil symbols and arrows on the contact symbols. Here is an example of a
time-delay relay contact used in a motor control circuit:

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Figure 3.11: Time-delay relay contact

In figure 3.11, the motor delays start-up until three seconds after the switch is thrown to the "Run"
position, but will stop immediately when the switch is returned to the "Stop" position. The relay contact
is referred to as normally-open, timed-closed, or NOTC. It is alternatively referred to as a normally-
open, on-delay contact.

3.12 RELAY APPLICATION FOR LADDER DIAGRAM

The switch logic circuit application in relay shows a relay with two NO contacts. One contact is used
as an interlock around the START push button. Thus, an interlock circuit is a path provided for
electrical energy to the load after the initial path has been opened. The second relay contact is used
to energize a light. Remember that when a relay coil is energized, the NO contacts close. The circuit
can be de-energized by operating the STOP push-button switch.

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EXERCISE:

1) Draw a typical relay and schematic symbol diagram.

2) With the aid of suitable diagram, explain the relay operation.
3) Select a switch configuration and draw a solution for the following control problem:
A switch should start a 110VAC motor and control two 12V DC indicator lamp. An illuminated red
lamp indicates that the motor is not powered, and an illuminated green lamp indicates that the
motor is powered.
4) As shown in Figure 4, explain the purpose of the protection diode as shown.
State TWO (2) types of protection circuit.

Figure 4

5) Identify each of these relay logic functions by name (AND, OR, NOR, etc.) and complete their
respective truth tables:

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