CHAPTER 3

RELAY

DEM3
INDUSTRIAL ELECTRONIC
 Course Learning Outcomes
CLO1:
Apply the mechatronic devices, switches, relays, solenoid,
electronic control devices, sensor and telemetry system in
industrial application. (C3)
CLO2:
Construct the circuit of relays, and sensors according to
operational principle.(P4)
Introduction

What is a relay?

an electromechanical device

The relay offers a simple ON/OFF switching action and

response to a control signal under electromagnetic
conditions
Relay symbol
Relay Structure
Mechanism principle of relay
• When electric current flows through the coil of wire, a magnetic
field is produced
• (magnetic north and south pole are produced across the gap
separating the coil and armature, acting like an electromagnet)
• This pulls a movable arm that forces the contact to open or close
• (the magnetic field ‘pull in’ the armature and close the NC contact
to NO contact)
• When the electrical current stops flowing, the armature return back
to normal position
• Relay actuated when the sufficient current intensity produced
enough force to overcome spring tension
• This might then be used to supply a current to a motor or perhaps
an electric heater in a temperature control system.
How do it function
• The electrical relay offers a simple ON/OFF switching
action in response to a control signal. When a current
flows through the coil of wire a magnetic field is
produced. This pulls a movable arm that forces the
contact to open or close. This might then be used to
supply a current to a motor or perhaps an electric
heater in a temperature control system.
• Time-delay relays are control relays that have a
delayed switching action. The time delay is usually
adjustable and can be initiated when a current flows
through the relay coil or when it ceases to flow through
the coil.
Relay applications
• Boring
• Drilling
• Milling
• Grinding
Specification
• 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. This voltage level is set
by the National Electrical Manufacturer
Association (NEMA).
Relay Symbols
Relay Coil

NO Relay Contact

NC Relay Contact

Time-Delay Relay Coil

Relay Symbols
NO (time delayed after
energizing)

NC (time delayed after

energizing)

NO (time delayed after

de-energizing)

NC (time delayed after

de-energizing)
Circuit symbols of relays

C denotes the common terminal in SPDT and DPDT types

Relay Basics
The basics for all the relays are the same.
Take a look at a 4 – pin relay shown below.
There are two colours shown. The green
colour represents the control circuit and the
red colour represents the load circuit. A
small control coil is connected onto the
control circuit. A switch is connected to the
load. This switch is controlled by the coil in
the control circuit. Now let us take the
different steps that occur in a relay.
Energized Relay (ON)
As shown in the circuit, the current flowing
through the coils represented by pins 1 and
3 causes a magnetic field to be aroused.
This magnetic field causes the closing of the
pins 2 and 4. Thus the switch plays an
important role in the relay working. As it is a
part of the load circuit, it is used to control
an electrical circuit that is connected to it.
Thus, when the relay in energized the
current flow will be through the pins 2 and 4.
De – Energized Relay (OFF)
As soon as the current flow
stops through pins 1 and 3, the
switch opens and thus the open
circuit prevents the current flow
through pins 2 and 4. Thus the
relay becomes de-energized
and thus in off position.
Keypoints
• When a voltage is applied to pin 1, the
electromagnet activates, causing a
magnetic field to be developed, which
goes on to close the pins 2 and 4 causing
a closed circuit.
• When there is no voltage on pin 1, there
will be no electromagnetic force and thus
no magnetic field. Thus the switches
remain open.
Relay Applications
• Relays are used to realize logic functions. They play a very
important role in providing safety critical logic.
• Relays are used to provide time delay functions. They are
used to time the delay open and delay close of contacts.
• Relays are used to control high voltage circuits with the help
of low voltage signals. Similarly they are used to control high
current circuits with the help of low current signals.
• They are also used as protective relays. By this function all
the faults during transmission and reception can be detected
and isolated.
Relay Selection
• Protection – Different protections like contact protection and coil
protection must be noted. Contact protection helps in reducing
arcing in circuits using inductors. Coil protection helps in reducing
surge voltage produced during switching.
• Look for a standard relay with all regulatory approvals.
• Switching time – Ask for high speed switching relays if you want
one.
• Ratings – There are current as well as voltage ratings. The current
ratings vary from a few amperes to about 3000 amperes. In case
of voltage ratings, they vary from 300 Volt AC to 600 Volt AC.
There are also high voltage relays of about 15,000 Volts.
• Type of contact used – Whether it is a NC or NO or closed contact.
• Select Make before Break or Break before Make contacts wisely.
• Isolation between coil circuit and contacts
Ladder Diagram (Example 1)

• One contact, CR-1 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, START button has been opened.
• The second relay contact, CR-2 is used to energize a light.
• Remember that when a relay coil is energized, the NO contacts of CR-1
and CR-2 close.
• The relay can be de-energized and light off by operating the STOP push-
button switch.
 Ladder Diagram (Example 2)

• Figure above shows the addition of a selector switch, fuse, pilot light and a second
relay.
• When the selector switch is operated to the ON position, electrical energy is available
at the two vertical sides of the circuit. The green light is energized, showing that the
operation has been completed.
• One additional relay contact is added in the circuit from relay 1 CR. This contact closes
when the relay1 CR is energized and it, in turn, energizes a second relay coil 2 CR.
• The operating circuit can be de-energized by operating the STOP push-button switch.
Application on relay and switch
Basic ladder diagram for the
combination of switch and relay:

SELF
AND OR
HOLDING
AND
S1
C1

S2
C2

L
C1 C2
OR
S1
C1

S2
C2
C1

C2
SELF HOLDING
C1

STO START
P
C1

L
C2
 Ladder Diagram (Example 3)
• PB2 on -> current flow through contact relay CR2 (NC) ->
coil relay CR1 energize & L1 on
• Contact relay CR1 close contact & interlocking around the
PB2 -> current still flowing as the PB2 is released.
• PB3 on -> current can’t flow as the CR1 NC is now open
contact until coil relay CR1 de-energize.
• PB1 pressed -> circuit break -> current can’t flow through
whole circuit -> coil relay CR1 de-energize & L1 off
• PB3 on -> current flow through contact relay CR1 (NC) ->
coil relay CR2 energize & L2 on
• Contact relay CR2 close contact & interlocking around the
PB3 -> current still flowing as the PB3 is released.
• PB1 pressed -> circuit break -> current can’t flow through
whole circuit -> coil relay CR2 de-energize & L2 off
• Coil relay CR1 and coil relay CR2 can’t energize
simultaneously.
Keypoints
• a relay is in essence a switch with
two position on and off
• Relay are controlled by
electromagnetism that enables small
current to control a much larger
current