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Product News | Power Distribution & Energy


HIGH VOLTAGE DC CONTACTOR RELAYS FROM LITTELFUSE



January 18, 2023

High current and high voltage DC contactor relays for electric, hybrid, and
industrial applications such as charging station, battery power supply, DC power
control, circuit protection, and other switch controls. Can also be used in
uninterruptible power supply and other electronic control systems. 


WHY SHOULD YOU USE A RELAY?

The main job of a relay is to enable remote switching within an electrical
system. A relay allows switching of a high current circuit by a low current
signal. This allows the relay to be placed close to the power source, or load to
be switched, so that expensive high current cabling is minimized, while still
giving easy access to the operator to turn the relay on or off.


APPLICATION CONSIDERATIONS

What is your application? Knowing your application will be key to selecting the
right solution.

Load Type

Is it going to be switching a load on and off frequently so it needs high
switching cycle life? Or will it be used to turn on a load and keep it on for a
long time, and it needs to be very efficient with minimal losses? It is
important to understand how the relay will be used.

Load Ratings Requirements

What is the application voltage? What are the continuous and peak currents? What
kind and size of wire will be used to connect the power terminals? Understanding
your application electrical load requirements will help with your relay
selection

Mounting Locations

Where will the unit be mounted? Will it be protected in an enclosure like a
charging station or 5G base station or exposed to the elements in an engine bay
or on a frame rail? Identifying the required mounting location is important as
it will affect the selection of the relay for maximum life.

Circuit Protection

Do I need to consider circuit protection with the relay? How will I integrate
them so I have an efficient installation? Protecting a relay’s main power wires
that run to secondary power distribution is a frequently overlooked aspect of
high current relay applications.


ELECTRICAL CONSIDERATIONS

It is important to understand the specific application electrical requirements
before selecting the most appropriate relay. Electrical considerations like
voltage, amperage, coil type, high current terminals, smart connectivity, and
others help drive relay selection to best match the application

Voltage

The voltage of a relay has two separate voltage ratings. One rating for the coil
and one rating for the main contacts. In many cases, they are the same but also
can be very different. In High Voltage relays, they tend to be very different,
with relay contacts rated at 1000V to handle the high voltage required whilst
being operated by coils of 12V-96V.

Amperage

There are several different current ratings that need to be considered when
picking a DC contactor relay.

Continuous Carry Current

The current that the relay can carry essentially forever without the temperature
rising above a set value.

Inrush Current or Starting Current

A short duration current value that is the maximum the switch can withstand
without raising the temperature over that same value (10-60 secs). Examples
include starting event, incandescent light in-rush, Inductive load start up,
etc. It is very important to match the in-rush current rating of the relay to
the application, especially in applications with inductive or capacitive loads.

Coil Types

Monostable relays (also sometimes referred to as normally open) turn on when the
coil is ON and turn OFF when the coil is OFF. They have one position (usually
OFF) that they return to when the coil is turned OFF. This type of relay is
usually designed to control a specific load that is turned ON and OFF as needed
in the vehicle.

Bi-stable (or latching relays) are relays that are designed to stay in either
the ON or OFF positions with no power applied. Once they receive an activation
signal to change state from OFF to ON (or ON to OFF) they do not consume any
power.

Coil Terminals

These smaller terminals connect the solenoid coil of the relay to the control
input. In sealed relays, frequently these are in a sealed connector.

High Current Terminals

In high current relays, the most common style of main terminals are studs or
screws. These usually range from M6 to M12, with the size usually corresponding
to the relay rating (larger studs for larger currents). Tin or Silver plated
terminals help prevent bad contact by limiting corrosion. It is beneficial to
always try to use stainless steel hardware as this eliminates the issue of
galvanic corrosion

Smart Connectivity

Relays can incorporate many smart features to control the switching. Examples
include delay timers, voltage sensors, or bussed connection via CAN or LIN
communications.


MORE INFORMATION

Download the DC Contactor Relay Selection Guide


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costintensive manual inspections. This condition data is also an essential
component for implementing smart and flexible manufacturing – a key to IIoT.

 

 

 

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hoist control systems, it brings new levels of reliability, flexibility and ease
of use to smaller companies on greenfield projects or upgrades. It can also help
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Unscheduled stops and faults in the production process can be avoided using our
new multi-functional condition monitoring sensor. This intelligent sensor
provides you with condition information which you can use for automating
costintensive manual inspections. This condition data is also an essential
component for implementing smart and flexible manufacturing – a key to IIoT.

 

 

 

Read More Condition Monitoring Sensor With Integrated Data PreprocessingContinue

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performance in a highly compact package can be an enormous advantage. With this
in mind, encoder manufacturer POSITAL has unveiled a fully functional prototype
of their new miniature multi-turn kit encoder for integrated motor feedback.
With a diameter of only 22 mm and a height of 23 mm (0.87”/0.9”), the new device
is the world’s smallest multi-turn kit. It features a self-powered rotation
counter that does away with the need for backup batteries or complex gear
systems.

 

Read More Introducing the World’s Smallest Multiturn Absolute Kit Encoders – New
22 mm Mini Multi-turn Kit Encoder for Integrated Motor FeedbackContinue

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FUNCTIONALITY

The SIRIUS 3RW55 Failsafe soft starters are the first to feature the integrated
Safe Torque Off (STO) function. This ensures that the motor comes to a complete
standstill if an operator initiates an emergency shutdown. The motor then
remains in this state until the restart interlock is used to restart it. 

 

 

 

Read More Siemens Introduces First Soft Starters with Integrated Safe Torque Off
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--------------------------------------------------------------------------------


EDITOR’S PICK: WEBINAR TOMORROW


UPCOMING LIVE WEBINAR ON PLC-BASED APPLICATIONS BY SIEMENS DIGITAL INDUSTRIES



With PC-based automation, you can implement applications and solutions that far
exceed the functions of a classic controller. SIMATIC PC-based products offer
you a flexible, innovative platform with long-term availability that gives you a
home field advantage when meeting the challenges of the digital factory for your
machines and plants. Join us to learn more about our versatile Software PLC
offerings for distributed and PC-based applications.

Presented by: Hrishi Desai

Register now

--------------------------------------------------------------------------------

--------------------------------------------------------------------------------


LATEST ARTICLES


 * CONSERVING POWER AND CO2 EMISSIONS WITH PREMIUM EFFICIENCY MOTORS
   
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   motor efficiency vs your installed motors Premium efficiency motors. How much
   power consumption aka money are you spending that you do not have to? Take a
   minute while having your coffee to see if you can save money. The process of
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   Cavitation can occur when the inlet pressure of the… Read More…


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