BG LI-IN RELAYS

Company Profile
BG LI-IN
• We are closely held and professionally managed group of companies having 13 units all over India.
Each unit is headed by a professional .

The Group is into diversified activities in:

• Automotive - Manufacturing Aluminum Die Casting Components, Fastners, Wheel assembly and Auto Electricals.
• Home appliances - Manufacturing of Condensers, Motherboards for television, Cooler, water purifiers etc.
Auto Electricals - Magnetos, CDI, Switches, HT Coils, Relays.

The group has Joint venture/Technical collaboration from Taiwan for Relays under the name of
BG LI-IN Electricals Pvt. Ltd. Aurangabad.

An ISO TS 16949 Certified

BG LI-IN PROFILE
• Started in year 2000 for manufacturing Relays and Flashers. • Overall premises 9,000 sq. mtrs.
• Active built-up area 900 sq. mtrs. • 93 employees with average age about 30 years.
• State of the art machining set-up including Uni-Graphics backup. • We have a state of art automatic manufacturing facility.
• The entire set up is fully backed up by own power generator.

OUR PRODUCTS
• ON OFF & power relays from 5A to 70A. • Starter relays from 100A to 250A.
• Mini Relays. • ISO Relays.
• Flashers from 22W to 44W.

SALIENT FEATURES
• Conveyorised production. • Temperature control, dust proof environment.
• Trained & experienced manpower. • Ability to handle large volumes.
• On line automatic testing facility for PCB relays. • Automatic manufacturing Line.
• Total solution from concept to manufacturing. • System based on TS 16949 and aspiring for UL certification.
• Multi bobbin winding machine. • Capacity to produce 8.5 million relays per annum.
BG LI-IN

Index
Index
Page No.

Vision / Quality Policy 2

Production & QA 3

Approvals & Certificates 4

Introduction - Electro Mechanical Relays 5,6

Automotive Relay 7 DMR-101, 102, 201, 202

8 DMR-301, 302, 303, BGY401
9 BGR-203, 204, 205, 212
10 BGR-213, 214, 215, 216
11 BGR-208, 209, 210, 211

Power Relay 12 BGY-303H, 224, 224T, 224TE

13 BGY-228H, 223H, 221H,
440-2

Flasher 14 BGF103, 104, 105, 106

Ordering Information 15

Relay - Technical Terms 16,17

Forms of Relay Contacts 18

Relay Contact Material - Characteristics 19, 20

Contact Protection Circuits 21

 V I S I O N
We want to be a family owned, professionally
managed, technology oriented company run by
motivated individuals, adhering to fair business
practices, to achieve a common goal of customers &
shareholders delight.

R. N. BAGLA
Date : 1st October 2007 CHAIRMAN & MANAGING DIRECTOR

Quality Policy

"WHERE QUALITY IS RELIGION"

We are committed :

• To strive for excellence in every activity through continual improvement in the

quality of products manufactured and process used.

• To enhance quality awareness at levels through training.

• To do things right, the first time and every time.

2
 Production & QA

We are aiming -
At learning customer's demands forever

What is important to the customer is important to BGLI-IN

3
 Approvals & Certificates
BG LI-IN

ST
ERTL

ERDA

4
 Introduction - Electro Mechanical Relays

Magnetic system
The magnetic circuit consists of non-moving metal parts such as the core, yoke and a movable armature, and an air
gap between the armature and the pole area of the core.

How it works
The magnetic field is generated by a coil consisting of copper wire wound in layers around the bobbin in which there is an iron
core. If voltage is applied to the coil terminals a current (Ohms law I=V/R) flowing through the coil generates a magnetic field
and hence magnetic flux. This induced magnetic field/flux is directly proportional to the coil current and the number of turns of
the coil (H =n x I, H=magnetic field, n=number of turns, I =coil current).
When the magnetic field is strong enough, it will pull in the armature towards the core, closing the magnetic circuit and actuating
the armature. The moving armature directly or indirectly operates the relay contacts.
Although the current is the primary factor in generating flux and the pull force in magnetic system, it is common practice to
work with voltages to select and specify the relay coil.

Coil energization
The coil must be energized sufficiently by the power source to generate the required magnetic field and force to operate the
system at all times and under various conditions. Together with the magnetic system, the coil design has a major effect on
various parameters such as sensitivity, operating speed, power consumption, maximum operating temperature, etc.
The gradually increasing method of applying rated coil voltage to the coil should not be used. Rated coil voltage should be
impressed fully by means of a switching circuit. To guarantee accurate and stable relay operation, the relay coil has to be
energized with a stabilized power source.

DC Coil The power source for DC operated relays should be in principle be either a battery or a DC power supply with a
maximum ripple of 5%. Incase where power is supplied by a rectification circuit, the operate, holding and dropout voltage may
be higher and vary with the ripple percentage. With a pulsed coil supply the coil current has to be above the holding current at all
times. If the current drops below this level, the armature will start to open and buzzing of the relay and increased contact wear
will result.

Coil inductance
As a result of the high number of turns, the soft iron magnetic circuit, and low magnetic resistance, relay coils have a relatively
high inductance. When switching off the supply voltage a high voltage peak will be induced in the coil due to the back EMF,
making / protection circuits necessary (such as flywheel diodes) to protect coil driving transistors and other electronic
components.

In the case of a circuit with flywheel diodes the inductance keeps the coil current flowing after the coil voltage has been
switched off and the induced coil current is sufficient to keep the relay in the pulled-in state delaying the dropout.

The AC coil impedance (resistance + reactance) is higher than the resistance and increases with the frequency of the coil
supply. Thus, the coil current at 60Hz is lower compared to a 50Hz supply.

Power consumption
The coil, while energized, consumes power. The power for actuating the relay is dependant on relay design.
The power consumption for DC coils is the product of coil voltage and coil current or according to Ohms law i.e.
P=V*I=V2/R=12R, given in Watts.
The lower the input power, lesser the heat generated. This can be particularly important in temperature critical applications
such as those where relays are densely packed on a PCB.

Coil heating
A negative effect of power consumption is the heating of the coil and, in turn, the entire relay. The coil temperature is a result of:
• Ambient temperature
• Self heating (Due to coil Power consumption = V*I)
• Induced heating (Due to heat generated by contact system)
• Magnetization losses (Due to eddy currents)
• Other sources (Due to components in the vicinity of the relay)
Due to coil heating coil resistance increases. Resistance at elevated temperature is expressed by R,= Ro[(1 +a(T-23)]

5
 Introduction - Electro Mechanical Relays

Where Ro is the resistance at ambient temperature (23°C), T is the elevated temperature and a is the temperature 'coefficient
on winding wire (Copper)

During circuit design, care has to be taken that calculations are made under the respective "worst case" conditions, such as the
highest possible coil temperature (ambient temperature, self heating of coil and induced heating with applied contact load) for
pick-up voltage.

Pick up voltage change due to coil temperature rise.

Usually the nominal coil resistance of relay is given for an ambient temperature of 20 deg. C. A coil at this temperature is called
cold coil. A coil heated by effects listed above is called a hot coil.

For a given coil, the pick-up current remains the same at any condition. The pick-up current depends on the coil resistance and
the pick-up voltage (lpick-up= Vpick-up / R-coil)' Coils of most of the relays are made of copper wire. The resistance of copper
wire increases or decreases by 0.4% per degree C. Due to the increase in coil temperature the coil resistance increases as per
the ratio mentioned above. Hence the pick-up voltage for a hot coil should be higher to generate required pick-up current.

For example in DMR 102 relays the pick up voltage for 12VDC coil is 9.6 VDC and coil resistance is 400 Ohms at 20 deg. C. i.e.
Ipick-UP = 24mA

When the coil temperature is increased to 40 deg. C the coil resistance will be increased to 432 Ohms. Hence the pick up
voltage will be 10.36 VDC (pick-up current remains the same). i.e. an increase in temperature by 20 deg. C increases the pick up
voltage by 0.76 VDC.

For relays operating with higher duty cycles, the pick-up voltage may increase slightly for each successive cycle due coil
temperature rise.

Coil Drive circuit protection

Normally DC Relays are operated through semi conductor devices. Due to the inductance of the coil, high voltage peaks are
induced (in the form of back emf) when the coil supply is switched off. To protect the relay control transistors or contacts of
other control relays against this surge voltage, protection in the form of flywheel diodes or other more elaborate circuits have to
be used.
Flywheel diodes are connected parallel to the coil in reverse polarity to the coil supply. While discharging the back emf flywheel
diodes provide a low resistance path protecting the driving circuit. The back emf dies gradually by forming loops. Using a
flywheel diode increases the release time of a relay.
In automotive relays a high value resistor is connected across the coil to serve the purpose. The back emf will get dissipated
in the resistor. The impact of parallel resistor on the release time will be less compared to flywheel diode.

Basics on relay handling

• Avoid ultrasonic type cleaning of all type of relays.
• To obtain initial performance through out life, avoid dropping or hitting the relay
• Case of the relays should not be removed.
• Sealed relays should be used for installation where adverse environment conditions, presence of sulphides,
organic chemicals etc.
• Always apply rated voltage to relay coil.
• Do not switch voltage & Currents that exceeds the designated values
• Use flux resistant / Sealed relays for automatic soldering.
• Do not touch terminals with bare fingers which would result in poor soldering.

6
 Automotive Relay

Type DMR 101 DMR 102 DMR 201 DMR 202

Outer View

Dimensions (mm) L x W x H 16 x 12.5 x 14.5 22.5 x 16.5 x 16.5 26 x 26 x 43 26 x 26 x 25

Contact Form 1A, 1C 1A, 1C 1A, 1B, 1C 1A, 1B, 1C
Contact Material Ag alloy Ag alloy Ag alloy Ag alloy
10A / 12VDC 15A / 28VDC 40A/12VDC, 70A/12VDC 40A/12VDC, 70A/12VDC
Contact Ratings
10A / 240VAC 15A / 125VAC 30A/24VDC, 70A/24VDC 30A/24VDC, 70A/24VDC
Max. Switching Voltage 28VDC / 240VAC 28VDC / 125VAC 28V DC 28V DC
Max. Switching Current 5A, 10A 10A, 15A 20A, 30A, 40A, 70A 20A, 30A, 40A, 70A
Switching Power Max. 120W, 2400VA 280W, 1250VA 480W 480W
Contact Resistance (Initial) m? 50 100 100 100
Coil Voltage 6V - 24V 6V - 24V 6V - 24V 6V - 24V
Coil Power Consumption 0.69W 0.45W 1.7W 1.7W
Dielectric Strength
Between Open Contacts 750V AC/1min 750V AC/1min 750V AC/1min 750V AC/1min
Between Coil & Contacts 750V AC/1min 1500V AC/1min 1000V AC/1min 1000V AC/1min

Insulation Resistance
100 100 100 100
M? (At 500V DC)
Life Expectancy (ops.)
5 5 5 5
Electrical 1 x 10 1 x 10 1 x 10 1 x 10
7 7 7 7
Mechanical 1 x 10 1 x 10 1 x 10 1 x 10
Operating Temp. Range -30° to + 85°C -40° to + 70°C -40° to + 80°C -40° to + 80°C
Operate Time (at nominal Voltage) 15 ms 15 ms 15 ms 15 ms
Release Time (at nominal Voltage) 10 ms 10 ms 10 ms 10 ms
Terminal Shape P. C. B. P. C. B. Plug-in Plug-in

85 85

Wiring Diagram 87a 87a

30 30
87 87

86 86
(Bottom View) (Bottom View)
5-1.3 3 17.9 3 17.9
Hole
8.4 8.4
4.6 4.6
16.5 max
12

12
Drilling Plan
85

85
2.25

16.8 16.8
87a

87a

2.5 12.2
87

87
30

30

2.0
86

86

22.5 max.

Weight (g) 6 12 32 31
General controller motor load, Boiler controller, Air Conditioner, A/C Compressor, Starter Motor, A/C Compressor, Starter Motor,
Internal wipers, door lock, UPS office automation, PLC Radiator Fan, Communication Radiator Fan, Communication
Applications Window Lifter, Alarm system Security System, Timer Equipment, Automatic Devices Equipment, Automatic Devices
Battery Disconnection Battery Disconnection

Cross Reference TYCO, SIEMENS VF4 TYCO, SIEMENS VF4

7
 Automotive Relay
BG LI-IN
Type DMR 301 DMR 302 DMR 303 BGY 401

Outer View

Dimensions (mm) L x W x H 19 x 21 x 16.5 23.4 x 21 x 19.2 23.4 x 21 x 18.7 14.5 x 16.8 x 13.2
Contact Form 1A, 1C 1A, 1C 1A, 1C 2(2 x 1C)
Contact Material Ag alloy Ag alloy Ag alloy Ag alloy
40A / 28VDC 40A / 28VDC 40A / 28VDC 20A / 14VDC
Rated Switching Current
40A / 240VAC 40A / 240VAC 40A / 240VAC 10A / 14VAC
Max. Switching Voltage 240VAC / 28VDC 240VAC / 28VDC 240VAC / 28VDC 14VDC
Max. Switching Current 10A, 20A, 30A, 40A 10A, 20A, 30A, 40A 10A, 20A, 30A, 40A 20A, 10A
Switching Power Max. 9600VA / 1120W 9600VA / 1120W 9600VA / 1120W 420W
Contact Resistance (Initial) m? 100 100 100 100
Coil Voltage 12V, 24V 12V, 24V 12V, 24V 12V, 24V
Coil Power Consumption 1.7W 1.7W 1.7W 0.81W
Dielectric Strength
Between Open Contacts 500V AC/1min 500V AC/1min 500V AC/1min 550V AC/1min
Between Coil & Contacts 1000V AC/1min 1000V AC/1min 1000V AC/1min 550V AC/1min

Insulation Resistance
100 100 100 100
M? (At 500V DC)
Life Expectancy (ops.)
5 5 5 5
Electrical 1 x 10 1 x 10 1 x 10 1 x 10
7 7 7 7
Mechanical 1 x 10 1 x 10 1 x 10 1 x 10
Operating Temp. Range -40° to +70°C -40° to +70°C -40° to +80°C -40° to +85°C
Operate Time 15 ms 15 ms 15 ms 15 ms
Release Time 10 ms 10 ms 10 ms 10 ms
Terminal Shape P. C. B. P. C. B. P. C. B. P. C. B.

9 10 5 4

Wiring Diagram 8 3

7 2
Schematic Schematic Schematic
6 1
Bottom View Bottom View Bottom View
4.3 14.9 ± 0.2 4.3 14.9 ± 0.2 4.3 14.9 ± 0.2
11.25
5.35 ± 0.1 3.75 ± 0.1 5.35 ± 0.1 3.75 ± 0.1 5.35 ± 0.1 3.75 ± 0.1
6-Ø1.3 3.75
6.35

6.35

6.35

9
1.5

1.5

1.5

1.5

1.5

1.5

10 5
5
14.2 ± 0.2

14.2 ± 0.2

14.2 ± 0.2

Drilling Plan 8 3
13.75
11.9 ± 0.2

1.6
11.9 ± 0.2

1.6
11.9 ± 0.2

1.2 1.2 1.6 1.2

6.25

2 2 2
7 2
6 1
1.6

1.6

1.6

4-Ø0.9
4.1 ± 0.1 4.1 ± 0.1 4.1 ± 0.1 11.25
12.3 ± 0.2 12.3 ± 0.2 12.3 ± 0.2

Weight (g) 18 23 21 10
Starter, Flashers, Wiper, Starter, Flashers, Wiper, Starter, Flashers, Wiper, Window Motors, Sunroof
Controller, Security System, Controller, Security System, Controller, Security System, Motors, Seat Adjustment
Applications
Car Alarm system, Heater Car Alarm system, Heater Car Alarm system, Heater Motors, Door locking System
Controller, Air Conditioner Controller, Air Conditioner Controller, Air Conditioner Immobilizers
TYCO V23072 TYCO V23072 TYCO V23072
Cross Reference HONGFA HFKP HONGFA HFKP HONGFA HFKP TYCO DMR V23084
P&B VKM P&B VKM P&B VKM

8
 Automotive Relay

Type BGR 203 BGR 204 BGR 205 BGR 212

Outer View

Dimensions (mm) L x W x H 22 x 16 x 24 23 x 15.5 x 37 30 x 30 x 44 26 x 26 x 46.5

Contact Form 1A, 1C 1A, 1C 1A 1A
Contact Material Ag alloy Ag alloy Ag alloy Ag alloy

Rated Switching Current 30A /12VDC 30A / 12VDC

10A / 28VDC 70A / 14VDC
20A /12VDC 20A / 12VDC
Max. Switching Voltage 28VDC 28VDC 28VDC 28VDC
Max. Switching Current 10A, 20A, 30A 10A, 20A, 30A 10A 150A
Switching Power Max. 840W 840W 480W 1880W
Contact Resistance (Initial) m? 100 100 100 100
Coil Voltage 12V, 24V 12V, 24V 12V, 24V 12V, 24V
Coil Power Consumption 1.3W 1.3W 2.4W 2.6W
Dielectric Strength
Between Open Contacts 500V AC/1min 500V AC/1min 500V AC/1min 500V AC/1min
Between Coil & Contacts 1000V AC/1min 1000V AC/1min 750V AC/1min 750V AC/1min

Insulation Resistance
10 10 1 1
M? (At 500V DC)
Life Expectancy (ops.)
5 5 5 5
Electrical 1 x 10 1 x 10 1 x 10 1 x 10
7 7 7 7
Mechanical 1 x 10 1 x 10 1 x 10 1 x 10
Operating Temp. Range -30° to + 105°C -30° to + 105°C -30° to + 85°C -30° to + 80°C
Operate Time 10 ms 10 ms 15 ms 15 ms
Release Time 7 ms 7 ms 10 ms 10 ms
Terminal Shape P. C. B. / Plug in Plug in Plug in Plug in

Wiring Diagram

30 85 86 87 87a 30 85 86 87 30 85 86 87 87b 30 85 86 87

30 17.9
9.5 ±0.1

22±0.5 23 Max.
16.8±0.2 8.4
85
15.5±0.5
9±0.15
16±0.5

0.5±0.1
9±0.15

30
26±0.5
+0

2±0.1

87 30
16.8

Drilling Plan
17.9±0.2

30

86
8.0±0.1

87b
3±0.15 8±0.15 86 87 85
3±0.15
8±0.5 6.3±0.1
14±0.15
14.0±0.15 26±0.5
8±0.15

Weight (g) 15 17 39 41

Head Lamp Control, Starter Head Lamp Control, Starter Starter Motor, A/C Compressor,
D Compression,
Applications Motors, Defogger, Motors, Defogger,
Refrigerator
Radiator, Battery Disconnection
Radiator Fan, A/C Controls Radiator Fan, A/C Controls Defogger

Cross Reference

9
 Automotive Relay
BG LI-IN
Type BGR 213 BGR 214 BGR 215 BGR 216

Outer View

Contact Form 1A 1A 1A 1A
Contact Material CU CU CU CU
Nominal Voltage 12VDC 12VDC 12VDC 12VDC
Rated Coil Current Max. 4A Max. 4A Max. 4A Max. 4A
Rated Load 100A, 150A 100A, 150A 100A, 150A 100A, 150A

Voltage Drop between 100mV max. at 100A 200mV max. at 200mV max. at 200mV max. at
Load Terminal after Endurance 150A before Endurance 100A before Endurance 100A before Endurance

Maximum Switching Current 350A 350A 350A 350A

Operating Voltage Range 7V - 16V 8V - 16V 7V - 16V 8V - 16V
Pull in Voltage Max. 7V 8V 7V 8V
Maximum Drop Off Voltage 3V 5V 3V 3V
5 M? at 500VDC 5 M? at 500VDC
Insulation Resistance (min) 5 M? at 500VDC between contact 5 M? at 500VDC between contact
terminal & body terminal & body
Operating Temperature -20° to + 120°C -20° to + 120°C -20° to +120°C -20° to +120°C

20,000 cycle of 5 sec 20,000 cycle of 5 sec 20, 000 cycle of 5 sec 20, 000 cycle of 5 sec
ON & 30 sec OFF with ON & 30 sec OFF with ON & 30 sec ON & 30 sec
Endurance Test a load current of OFF with a load OFF with a load
a load current of
100A 12VDC 100A, 12VDC current of current of
100A, 12VDC 100A, 12VDC
Terminal Shape Bolt Terminal Bolt Terminal Bolt Terminal Bolt Terminal

Dimensions (mm)

Weight (g) 206 380 185 310

Starter Relay for 2, 3, & 4 Starter Relay for 2, 3, & 4 Starter Relay for 2, 3, & 4 Starter Relay for 2, 3, & 4
Applications Wheelers Wheelers Wheelers Wheelers

Cross Reference

10
 Automotive Relay

Type BGR 208 BGR 209 BGR 210 BGR 211

Outer View

Dimensions (mm) L x W x H 25 x 16 x 37 26 x 26 x 53 26 x 26 x 25 26 x 26 x 46.5

Contact Form 1A, 1C 1A 1A 1A
Contact Material Ag alloy Ag alloy Ag alloy + Tungsten Ag alloy + Tungsten
30A / 12VDC 70A / 14VDC
Rated Switching Current 30A/12VDC 100A / 14VDC
20A / 12VAC 35A / 28VAC
Max. Switching Voltage 28VDC 28VDC 28VDC 28VDC
Max. Switching Current 10A, 20A, 30A 30A 240A 350A
Switching Power Max. 840W 480W 840W 1200W
Contact Resistance (Initial) m? 100 100 100 100
Coil Voltage 12V, 24V 6V-24V 12V, 24V 12V, 24V
Coil Power Consumption 1.3W 1.7W 1.7W 3.5W
Dielectric Strength
Between Open Contacts 500V AC/1min 750V AC/1min 750V AC/1min 750V AC/1min
Between Coil & Contacts 1000V AC/1min 1000V AC/1min 1000V AC/1min 1000V AC/1min

Insulation Resistance
10 100 100 1
M? (At 500V DC)
Life Expectancy (ops.)
5 5 5 5
Electrical 1 x 10 1 x 10 1 x 10 1 x 10
7 7 7 7
Mechanical 1 x 10 1 x 10 1 x 10 1 x 10
Operating Temp. Range -30° to +105°C -40° to + 80°C -40° to +105°C -30° to +105°C
Operate Time (at nominal Voltage) 10 ms 15 ms 15 ms 15 ms
Release Time (at nominal Voltage) 7 ms 10 ms 10 ms 10 ms
Terminal Shape Plug-in Plug-in Plug-in Plug-in

Wiring Diagram

30 85 86 87 30 85 +86 87 87a 30 85 86 87 30 85 86 87

3 17.9 3 17.9
17.9
9.5 ±0.1

25 Max.
8.4 8.4
4.6 4.6 8.4
85
15.5±0.5
9±0.15

26±0.5

87 30
16.8

Drilling Plan
85

85

86

16.8
87

87a

87

16.8
30

30

8±0.15
3±0.15
14±0.15 6.3±0.1
86

86

8±0.15 26±0.5

Weight (g) 18 35 42 40
A/C Compressor, Starter Motor, Starter Motor, window Defogger Starter Motor, window Defogger
Head Lamp Control, Starter
Radiator Fan, Communication A/C Blower, Radiator Fan, A/C Blower, Radiator Fan,
Applications Motors, Defogger,
Equipment, Automatic Devices Battery Disconnection Battery Disconnection
Radiator Fan, A/C Controls
Battery Disconnection

Cross Reference

11
 Power Relay
BG LI-IN
Type BGY-303H BGY-224 BGY-224T BGY-224-TE

Outer View

Dimensions (mm) L x W x H 19.5 X 15.8 X 15.3 32.5 X 27.5 X 20.5 32.5 x 27.5 x 28 32.5 x 27.5 x 20
Contact Form 1A, 1C 1A, 1B, 1C 1A, 1B, 1C 1A, 1B, 1C
Contact Material AgAlloy AgAlloy AgAlloy AgAlloy
1A-40A/250VAC/36VDC 1A-40A/250VAC/36VDC 1A-40A/250VAC/36VDC
Rated Switching Current 15A, 125VAC/28VDC
1B, 1C-30A/250VAC/30VDC 1B, 1C-30A/250VAC/30VDC 1B, 1C-30A/250VAC/30VDC
Max. Switching Current 3A, 7A, 10A, 12A, 15A 30A, 40A 30A, 40A 30A, 40A
Contact Resistance (Initial) m? 100 50 50 50
Coil Voltage 3-48VDC 3-110VDC 3-110VDC 3-110VDC
Coil Power Consumption 0.36/0.45 W 0.6W, 0.9W 0.6W, 0.9W 0.6W, 0.9W

Dielectric Strength 1500VAC

Between Open Contacts 750VAC 4000VAC (without pin 6) 1500VAC 1500VAC
Between Coil & Contacts 1000VAC 1500VAC (with pin 6) 2500VAC 2500VAC
Insulation Resistance
250 1000 1000 1000
M? (at 500V DC)
Life Expectancy (ops.)
5 5 5 5
Electrical 1 x 10 1 x 10 1 x 10 1 x 10
7 7 7 7
Mechanical 1 x 10 1 x 10 1 x 10 1 x 10
Operating Temp. Range -40o to + 85o C -55o to + 125o C -55o to + 100o C -55o to + 125o C
Operate Time (at nominal Voltage) 8 ms 10ms 10ms 10ms
Release Time (at nominal Voltage) 5 ms 8ms 8ms 8ms
Terminal Shape P. C. B P. C. B P. C. B P. C. B

Wiring Diagram

5-Ø1.3 3-Ø2.1 3-Ø2.1 3-Ø2.1

2.54

2.54

2.54

17.8 17.8
15.4 7.7

17.8
15.4 7.7

15.4 7.7
15.4

15.4
12

Drilling Plan

3.8 2-Ø1.1 3.8 2-Ø1.1 3.8

2-Ø1.1
8.9 8.9
2 12.2 14 14 14

Weight (g) 12 30 35 31
A/C Systems, Ventilation, A/C Systems, Ventilation, A/C Systems, Ventilation,
Office Automation, Timer, Power Conditioning Power Conditioning Power Conditioning
Applications Security Systems, Equipments, Heater, Security Equipments, Heater, Security Equipments, Heater, Security
Home Appliances, UPS Systems, Systems, Systems,

TYCO SIEMENS T90 TYCO SIEMENS T91 TYCO SIEMENS T91

Cross Reference
OMRON G8P OMRON G7G OMRON G7G

12
 Power Relay

Type BGY 228(H)

BGY228H BGY223H BGY221H BGY440-2

Outer View

Dimensions (mm) L x W x H 28.9 X 12.6 X 20.6 29 x 12.6 x 20.6 29 x 12.6 x 20.6 28 x 21.5 x 35
Contact Form 1A, 1C 1A, 1C 2A, 2C 2A, 2B, 2C
Contact Material AgAlloy AgAlloy AgAlloy AgAlloy
5A, 10A, 15A/120VAC, 28VDC
Rated Switching Current 5A, 10A/250VAC, 30VDC 2 x 5A/250VAC, 30VDC 2 x 5A/250VAC, 28VDC
3A, 6A, 7A/220VAC
Max. Switching Current 10A , 16A 10A 5A 5A
Contact Resistance (Initial) m? 100 100 100 100
Coil Voltage 3-48VDC 3-48 VDC 3-48 VDC 6-110 VDC / 6-120VAC
Coil Power Consumption 0.54/0.72W 0.54/0.72W 0.54/0.72W 0.9W

Dielectric Strength
Between Contacts 750VAC 1200VAC 1200VAC 1000VAC
Between Coil & Contacts 1500VAC 5000VAC 5000VAC 1500VAC

Insulation Resistance
100 1000 1000 1000
M? (At 500V DC)
Life Expectancy (ops.)
5 5 5 5
Electrical 1 x 10 1 x 10 1 x 10 5 x 10
7 7 7 7
Mechanical 1 x 10 1 x 10 1 x 10 2 x 10
Operating Temp. Range -40o to + 70o C -30o to + 70o C -30o to + 70o C -40o to + 70o C
Operate Time (at nominal Voltage) 15ms 15 ms 15 ms 15 ms
Release Time (at nominal Voltage) 8ms 8 ms 8 ms 8 ms
Terminal Shape P. C. B P. C. B P. C. B P. C. B / Plug-in

Wiring Diagram

21.5
3.5 3.5
20.3 5.08(3.5) 20.3 5.08(3.5)
6.4 6.3 4.1
7.5

5- 1.3
Drilling Plan
7.5

8-1.3
7.5

8-1.3 8-2.5
28

5.08(3.5) 5.08(3.5)

16.4 13.2

Weight (g) 13 11 13 35
Office Automation, Timer, Office Automation, Timer, Office Automation, Timer,
Temperature Controllers,
Security Systems, PLCs Security Systems, PLCs Security Systems, PLCs
Applications Timers, PLCs, Control Panel,
Home Appliances, UPS Home Appliances, UPS Home Appliances, UPS
Industrial Electronics
Industrial Electronics Industrial Electronics Industrial Electronics

HONGFA JZX-18FF
Cross Reference OMRON MY

13
 Flasher
BG LI-IN
Type BGF 103 BGF 104 BGF 105 BGF 106

Outer View

Flasher Type 2 Pin 2 Pin Solid State 2 Pin 2 Pin Solid State
Flash Rate 85c/m ± 10c/m 65 - 90 c/m 85c/m ± 10c/m 85c/m ± 10c/m

% Current On Time 35% to 60% 35% to 60% 40% to 60% 35% to 60%

Measuring Conditions
Voltage 12.8VDC 12VDC 12.8VDC 12VDC
Rated Load 10W x 2+2W 10W x 2+3.5W 21W x 2+2W 10W x 2 + 2W
Temperature o o o o o o o o
- 20 to + 55 C - 20 to + 55 C - 20 to + 55 C - 20 to + 55 C
Circuit Resistance 0.1 ? ± 0.01 ? 0.1 ? ± 0.01 ?
Starting Time 1.5 sec Max. 1 sec Max. 1.5 sec Max. 1 sec. Max.

At low load condition At low load condition

Remains lit at 10W Remains lit at 12W
Indication of a Bulb Failure flashing frequency flashing frequency
failure failure
will be doubled will be doubled

200H of working 200H of working 200H of working 200H of working

Durability Test Cycle Consisting of Cycle Consisting of Cycle Consisting of Cycle Consisting of
15 sec ON & 15 sec OFF 15 sec ON & 15 sec OFF 15 sec ON & 15 sec OFF 15 sec ON & 15 sec OFF
Voltage Drop 400mV Max. 400mV Max. 400mV Max. 400mV Max.
Terminal Shape Plug-in Plug-in Plug-in Plug-in

Relay
B Switch
L
Left Side Right Side
Wiring Diagram Switch
Battery
12V.2.5AH w w w w w
10 10 2 10 10

33.9 ± 0.5 8.5 ± 0.2

40.0 5.8
2.8 1.70 BGLI
38.5 ± 0.5

21Wx2+2W
12.8V
12.0 ± 0.5

Drilling Plan
35
15
21.5
26.5
40.0

1.7
4

FLASHER +0.5
8.5 -0.0 20 ± 0.3
+0.1
6.3 -0.0 17 ± 0.3

Weight (g) 25 23 25 35

Applications Turn Signal Indicator Turn Signal Indicator Turn Signal Indicator Turn Signal Indicator

Cross Reference

14
 BG LI-IN
Ordering Information

DMR 201 1C 12 S 30 XXX

Product Contact Nominal S-Sealed Rating Special application

Series form Coil Voltage if any
1A 6V 20A
1B 9V 30A
1C 12V 40A
18V 70A
24V

Notes :

15
 Relay - Technical Terms
BG LI-IN
Ambient Temperature: Temperature measured directly near the relay. The maximum allowed value may not be exceeded,
otherwise there is a chance for relay failure. (e.g. Coil overheating)

Bounce Time: Time interval between the first and final closing (or opening) of a contact, caused by a mechanical shock process
in contact movement. These shock processes are called contact bounce.

Break Contact: A contact that is closed in the rest state of the relay and open in the operating state. (refer Normally Closed
Contacts)

Bridging Contact: Special contact assembly in which two stationary contacts are connected by a movable bridge. In open
contact condition the bridge is separated on both its sides from the stationary contacts. Due to this double interruption a bigger
contact gap can be achieved. This is of advantage especially at very high contact loads or when there are safety requirements.
(refer Form Z type contacts)

Coil Current: The current (by design) drawn by the coil for generating the magnetic pull force. At the moment of switching the
coil On, the current is high earthen in continuous use.

Coil Resistance: Electrical resistance of the relay coil at reference temperature. Coil resistance varies with temperature.
(refer Pick-up voltage change due to coil temperature rise)

Contact Forms: This denotes the contact mechanism and number of contacts in the circuit. Form a contacts are also called
NO contacts or make contacts. Form B contacts are also called NC contacts or break contacts. Form c contacts are also called
Changeover contacts

Contact Gap: Distance between the contacts in the open contact circuit condition.

Contact Rating: The current a relay can switch ON and OFF under specified conditions of voltage and environmental
parameters.

Contact Resistance: Electrical resistance of a closed contact circuit, measured at the terminals of the relay with indicated
measuring current and voltage.

Change Over Contact: Compound contact consisting of a make contact and a break contact with a common contact spring.
When one contact circuit is open the other one is closed. (refer Form C type contacts)

Make Contact: A contact that is open in the rest state and closed in the operating state. (refer normally open contacts)

Continuous Current (Contacts): Maximum value of current (RMS value at AC), which a previously closed contact can
continuously carry under defined conditions.

Creepage Distance: Closest distance between two conductive parts, measured along the surface of insulated parts.

Dielectric Strength: Voltage (RMS Value in AC Voltage, 50Hz 1 min) the insulation can withstand between relay elements that
are insulated from one another.

Driver Protection circuit: When the coil energization is switched off, a very high negative peak voltage is produced by the coil
and it may reach more than 10-20 times the nominal coil voltage. Possible destruction of the semiconductor device (Driver) the
coil circuit is the result. A solution is provided by a driver protection circuit that is a damping component, which is connected in
parallel to the coil. It protects the driver but does slow the release time of the relay. Also known as coil snubber circuit.

Dropout Voltage: The Voltage at or below which all the contacts of an operated relay must revert to unoperated position.
Also known as release voltage.

Dust Proof Relays / Solder Proof Relay: Relay with case for protection against dust and touch. With specified solder
conditions are kept, no harmful amounts of flux or solder vapor penetrate into the relay.

Duty Cycle: Ratio of the duration of energization to the total period of intermittent duty.

Electrical Endurance (Electrical Life): Number of operations until switching failure of a relay under defined Conditions of
load and of ambient influences. The reference value specified for the life apply, unless otherwise specified, to a resistive load. At
lower contact loads a substantially longer electrical life is achieved. At higher loads the electrical life is reduced substantially.

16
 Relay - Technical Terms

Inrush Current: This value specifies the instantaneous current that may flow on the defined conditions. (Voltage, Power
Factor, Duration) when the contact closes. Depends on type of load.

Insulation Resistance: Electrical resistance, measured between insulated relay parts at a test voltage of 500VDC.

Material Transfer: During the switching procedure the arc heats up the two contacts differently, depending on the load and
polarity. This result in a material transfer from the hotter to the cooler electrode. With a higher DC loads on the contact, a 'pip'
is build up, the other contact loose material and it creates a chatter.

Maximum Carrying Current: The maximum current which after closing or prior to opening, the contacts can safely pass
without being subject to temperature rise in excess of their design limit.

Maximum Continuous Voltage: The maximum voltage that can be applied to relay coil continuously with out causing
damage.

Maximum Switching Current: The maximum current that can safely be switched by the contacts.

Maximum Switching frequency: The maximum switching frequency which satisfies the mechanical or electrical life under
repeated operations by applying a pulse train at the rated voltage to the operating coil

Maximum Switching Power: The maximum value that can be switched by the contacts without causing damage.

Maximum Switching Voltage: The maximum open circuit voltage that can be safely be switched by the contacts.

Mechanical Endurance (Mechanical Life): Number of switching operations without contact load during which the relay
remains within the specified characteristics.

Nominal Coil Power: Power consumption of the coil at nominal voltage and nominal coil resistance. Also known as Rated
Power.

Nominal Coil Voltage: The voltage by design intended to be applied to the relay coil. Also known as Rated Voltage.

Open Relay: Relay without case or cover.

Operating Power: Coil Power at which the relay operates

Operate time: The time from the initial application of power to the coil until the closure of the normally open contacts. It is
excluding bounce time.

PCB Relays: Relays designed for soldering into printed circuit boards.

Pick-up Voltage: The value of the voltage that should be applied to an un-operated relay coil at or below which all the contacts
of the relay should operate. Also known as Pull-in voltage / Must operate voltage.

Plug-in Relay: Relays that are held in the socket by flat Plug-in terminals.

Release Time: The time from the initial removal of power from the coil until the re-closure of the normally closed contacts. It
is excluding bounce time.

Sealed Relay: Plastic base and cover are sealed with epoxy resin, after soldering into the PC board the relay. may be cleaned in
liquid or coated with varnish. Provides a large measure of protection against aggressive ambient atmosphere. Also known as
immersion cleanable relays.

Shock Resistance: It specifies at which mechanical shock (multiple of gravitational acceleration 'g' at half since wave and
duration 11 ms) the closed contact has still not opened (failure criteria: contact interrupted for>10µ s).

Vibration Resistance: It specifies the amplitude or the acceleration in a defined frequency range at which the closed contacts
should still not open (failure criteria: contact interrupted for>10µ s).

17
 Forms of Relay Contacts
BG LI-IN
The contacts are the most important element of relay construction. Contact performance is influenced by contact material,
voltage and current values applied to the contacts, the type of load, frequency of switching, ambient atmosphere, form of
contact, contact switching speed and of bounce.
The contacts are practically not clean because the surfaces are covered by thin layers of low conductivity, semiconductor
properties or even isolating characteristics. These layers of oxides, sulphides and other compounds will be formed on the
surface of metals by absorption of gas molecules from the ambient atmosphere within a very short time. The growth of these
layers will be slowed down and eventually stopped as the layer itself prevents further chemical reaction. The resistance of these
layers increases with their thickness. To get a reliable electrical contact these layers have to be destroyed. This can be done by
mechanical or electro-thermal destruction.

Mechanical Cleaning
When the contacts are closing, the metal surfaces will collide and hit against each other several times (bouncing), causing elastic
deformation of the contact area and mechanical destruction of the thin layers. With high contact pressure also this could be
obtained.
The design of most of the relays allows the contact surfaces to wipe across each other destroying the non-conductive films on
the contact surfaces. This contact wipe is often enough to clean the surface and reduce resistance to an acceptable level, as well
as keeping the resistance stable through out the electrical life of the relay.

Electrical Cleaning
The low and non-conductive layers can also be destroyed by the effects of
a) electrical voltage (fretting)
b) current (heating of contact points)
c) thermal effects (high temperature due to electrical arc)

a) Fritting
The term fritting describes the electrical breakdown of oxide / foreign layer when a sufficiently high voltage is applied across a
closed contact. Due to the applied voltage and very short distance between the low potentials a high electric field is generated.
This electric field destroys the thin non-conductive layer and establishes a metal bridge electrically linking the two surfaces. The
value of fritting voltage depends on the contact material, composition and thickness of layers, conductivity and composition of
the contact surface.

b) High Currents.
High continuous currents and increased contact resistance due to the layers causes heating of the contact. The layers will
eventually be destroyed thermally and a larger effective contact area is created, reducing the constriction resistance.

c) Arc, sparks
Under certain circumstances an electric spark or arc will be generated during contact making or contact breaking under load.
The extremely high temperature of these arcs may destroy the contact layers and burn or disintegrate other contaminants or
particles in the vicinity of the point of contact.

Forms of Contacts

From A SPST -NO From C SPDT Form Y SPDT -NC-DB

From B SPST -NC From X SPDT -NO-DB Form Z SPDT DB

(2Circuit)

18
 Relay Contact Material - Characteristics

Contact Material Characteristics

Silver - Nickel Good Electrical conductivity and thermal conductivity. Exhibits low contact
AgNi 0.15 resistance, and widely used. Easily develops a sulfide film in a sulfide atmosphere.

Silver - Nickel Used for switching loads in the rage of > 100mA upto power switching. Good
resistance to contact wear and contact welding. Slightly high contact resistance.

AgNi 80:20 Mainly used in DC Switching particularly in automotive applications where high
inrush current occur.

Silver - Cadmium oxide Very Good resistance to contact wear and welding. Good thermal and mechanical
AgCdO stability. Used for switching inductive or high current loads like Motors, Solenoids
etc. High contact resistance and Sulphide films form easily.

Silver Tin Oxide High melting point and high thermal stability and therefore high resistance to
welding. Also contact erosion rate is lower because any arc spreads to the outside
of the contact preventing creation of a local hot spot and potential weld. High
AgSn02 contact life minimum material migration. AgSn02 is mainly used for application
involving high inrush current like lamp loads or inductive DC loads.

Palladium - Copper Greater Hardness, low contact wear and stable contact resistance. Good
PdCu corrosion and sulphidation resistance. Very low material migration compared to
other contact materials. Expensive. Mainly used for Flasher applications in Automobiles.

Tungsten W Highest melting point, high wear resistance with heavy loads, little transfer of material,
best suited for breaking heavy inductive loads.

Au clad Au with its excellent corrosion resistance is pressure welded onto a base metal.
(gold clad) Special characteristics are uniform thickness and the nonexistence of pinholes.
Greatly effective especially for low level loads under relatively adverse
atmospheres. Often difficult to implement clad contacts in existing relays due to
design and installation.

Surface Material
Au plating Similar effect to Au cladding. Depending on the plating process used, supervision
(gold plating) is important as there is possibility of pinholes and cracks. Relatively easy to
implement gold plating in existing relays.

Au flash plating Purpose is to protect the contact base metal during storage of the switch or device
(gold thin-film plating) with built-in switch.
However, a certain degree of contact stability can be obtained even when switching
loads.

19
 BG LI-IN
Electric Arc Switching
An electric arc is a current intensive gas discharge which occurs when opening a switch or as a result of a flashover. Under
certain circumstances the air path between two contacts are ionized due to very high electric field. Ionization causes the
normally non-conducting air conductive and its conductivity is maintained if sufficient energy is supplied. The arc represents an
additional resistive path in the load circuit. The minimum voltage and current required for generation and maintenance of a
stable arc depends on the contact material and the length of the air gap. (Ionization of air happens if a potential of 32V or more is
applied between two electrodes)

Due to extremely high temperature of the arc the surface of the contact will melt. Evaporation or sputtering of the contact
material leads to wear and material migration reducing the service life of the contacts.

Arc in DC Circuits
In DC circuits it is generally during contact breaking that arc occurs. When breaking contacts move further apart and as the gap
between the contacts increases the minimum voltage to maintain the arc normally rises above source voltage and the arc is
extinguished. If however the supply voltage / current is sufficiently high enough to maintain a stable arc across open contacts,
the relay will be destroyed.

In DC Inductive circuits, the counter emf generated whose magnitude Is equal to L "'1/2 (energy stored In the Inductance) act as
a secondary energy source which causes the arc to be maintained until the energy in the circuit has been converted to heat. This
leads to considerably longer arc duration. To prevent destruction of the contacts and to keep the arc duration within limits, the
switching voltage/current has to be within the maximum DC breaking capacity. (Higher the UR ratio or lower the power factor
of the load, the arc extinguishing time increases

Type of load and inrush current

The type of the load and its inrush current characteristics together with the switching frequency are important factors that
cause contact welding. Particularly for loads with inrush currents, measure the steady state current and inrush current and
select a relay that provides ample margin of safety. Table shown below illustrates the typical loads and corresponding inrush
currents.

Load Inrush Current and Time

Incandescent Lamp Load Mercury Lamp Load Fluorescent Lamp Load

IIIR = 10 to 15 times for 1/3 See approx IIIR = 5 to 10 times for 0.2 to 0.5 See approx IIIR = 3 times for 3 to 5 minutes approx

Motor Load Solenoid Load Coils Capacitive Load

I/R = 5 to 10 times for 1/1R = 10 to 20 times 1/1R = 3 to 10 times 1/1R = 20 to 40 times

0.2 to 0.5 Sec approx for 0.1 Sec approx for 1/30 Sec approx for 1/30 Sec approx

20
 Contact Protection circuits

Typical contact protection circuits are given in the table below.

Use of contact protective devices or protection circuits can suppress the Counter emf to a low level. However, note that
incorrect use will result in an adverse effect.

Circuit Features I Others Device Selection

Contact If the toad is a timer, leakage current

Inductive Load

flows through the CR circuit causing

faulty operation As a guide in selecting rand c, r: 0.5 to 10per 1µV
* If used with AC voltage, be sure the contact voltage c: 0.5 to 1µF per 1µA contact
r c impedance of the load is sufficiently current values vary depending on the properties
smaller than that of the CR circuit. of the load and variations in relay characteristics.
CR circuit

Capacitor c acts to suppress the discharge the

moment the contacts open. Resistor r acts to
limit the current when the power is turned on
Contact the next time. Test to confirm. Use a capacitor
Inductive Load

If the load is a relay or solenoid, the with a breakdown voltage of 200 to 300V. Use
release time lengthens. Effective when AC type capacitors (nonpolarized) for AC
r
connected to both contacts if the power circuits.
c supply voltage is 24 or 48V and the
voltage across the load is 1 00 to 200V.

The diode connected in parallel Use a diode with a reverse breakdown

causes the energy stored in the coil to voltage at least 10 times the circuit voltage
flow to the coil in the form of current and a forward current at least as large as the
Diode circuit

Contact
Inductive Load

and dissipates it as joule heat at the load current. In electronic circuits where
resistance component of the the circuit voltages are not so high, a diode
Diode inductive load. This circuit further can be used with a reverse breakdown
delays the release time compared to voltage of about 2 to 3 times the power
the CR circuit. (2 to 5 times the supply voltage.
release time listed in the catalog)
Diode and zener diode circuit

Contact
Inductive Load

Effective when the release time in Use a zener diode with a zener voltage
the diode circuit is too long. about the same as the power supply
voltage.

Using the stable voltage

characteristics of the varistor, this
Contact circuit prevents excessively high
Varistor circuit

Inductive Load

voltages from being applied across

r the contacts. This circuit also slightly
Varistor
c delays the release time. Effective
when connected to both contacts if
the power supply voltage is 24 or
48V and the voltage across the load is
100 to 200V.

Specifications Subject to change without prior notice.

21
 020 24484051
sascommunications

Distributor

Plot No. M-137, MIDC Industrial Area, Waluj, Dist. Aurangabad - 431 136. Maharashtra India.
Tel. : 91 - 240 - 3250408-12 Fax : 91 - 240 - 2554751
Email: - bgliin@baglagroup.com Web site : www.baglagroup.com