Panasonic ASCT1F46E Switch User Manual
Contents
1. 15 Coil When the short pulse signal is input to the relay coil the relay movable part may operate and touch short pulse lightly to the contact Therefore please avoid short pulse input 100ms or less since it may cause input contact welding due to less contact pressure Please test adequately for example when a relay is operated by external manual switch such as key switch 16 High When the switching frequency is high the electrical life may decrease Please confirm if there is a frequency high frequent switching caused by abnormal mode in actual use condition of switching 17 Low Note that if the contact has not been switched for a long time period organic film tends to be generated frequency on the contact surface which may cause contact instability of switching 18 Ambient Verify in the actual use condition since electrical life may be affected by use at high temperatures temperature 19 Connection If resistor diode zener diode are connected parallel to decrease the surge voltage when the relay coil of coil surge being turned off the relay release time will get longer and may decrease the electrical life or cause absorption light welding circuit 20 Sneak or Please test a relay in actual vehicle condition since there is a risk of deterioration at relay function or remaining switching performance such as slower release time which is caused by sneak current due to diode current zener diode capacitor mounted on a veh2. 15 PCB 2 SMD type mounting To meet the market demand for downsizing to smaller lighter and thinner products PC boards also need to proceed from insertion mounting to surface mounting technology To meet this need we offer a line of surface mount relays The following describes some cautions required for surface mount relay installation to prevent malfunction and incorrect operation Please contact us for or reflow soldering of through hole terminal type 1 What is a Surface Mount Relay 1 From IMT to SMT Conventional insertion mount technology IMT with some 30 years of history is now being replaced with surface mount technology SMT Solid state components such as resistors ICs and diodes can withstand high heat stresses from reflow soldering because they use no mechanical parts In contrast the conventional electro mechanical relays consisting of solenoid coils springs and armatures are very sensitive to thermal stress from reflow soldering We applied the experience gained from our advanced relay technologies to produce high performance electromagnetic relays compatible with surface mount technologies such as IRS and VPS Insertion Mount Technology amp Surface Mount Technology Insertion Mounting Technology IMT Components terminals are inserted into terminal holes of PC board and are soldered to copper pads on the other side of the board flow soldering Surface Mounting Technology SMT Components are p
3. In addition reliability of product design is becoming a serious concern for the manufacturing industry In short reliability has three senses i e reliability of the product itself serviceability of the product and reliability of product design 1 Reliability narrow sense durability Long life time MTTF Bio R T Low failure rate Lamda A MTBF Reliability Maintainabilit ilabili y Availability broad sense MTTR Preventive maintenance predicted maintenance Design reliability Human factor redundancy fool proof fail safe 3 Intrinsic Reliability and Reliability of Use Reliability is built into products This is referred to as intrinsic reliability which consists mainly of reliability in the narrow sense Product reliability at the user s site is called reliability of use which consists mainly of reliability in the broad sense In the relay industry reliability of use has a significance in aspects of servicing 2 Reliability Measures The following list contains some of the most popular reliability measures Degree of reliability R T MTTF T Time a RUT b MTTF c Safe life 1 Degree of Reliability Degree of reliability represents percentage ratio of reliability For example if none of 10 light bulbs has failed for 100 hours the degree of reliability defined in 100 hours of time is 10 10 100 If only three bulbs remained alive the degree of reliability is 3 10 30 The JIS Z8115 st
4. and the reverse blocking voltage should be about 3 times the value of the power source voltage Connection of a diode is an excellent way to prevent voltage surges but there will be a considerable time delay when the relay is open If you need to reduce this time delay you can connect between the transistor s Collector and Emitter with a Zener diode that will make the Zener voltage somewhat higher than the supply voltage Take care of Area of Safe Operation ASO 6 Coil 1 Relay drive 3 Snap action Characteristic of relay with voltage rise and fall impressed by means of It is necessary for the relay coil not to impress voltage slowly but to impress the rated voltage in a short circuit atransistor time and also to drop the voltage to zero in a short time Non pulse signal Pulse signal square wave VA J No good Without snap action Good Snap action 4 Schmitt circuit Snap action circuit Wave shaping circuit When the input signal does not produce a snap action ordinarily a Schmitt trigger circuit is used to produce safe snap action 1 The common emitter resistor Re must have a sufficiently small value compared with the resistance of the relay coil 2 Due to the relay coil current the difference in the voltage between at point P when Tzis conducting and at point P when Tiis conducting creates hysteresis in the detection capability of Schmitt circuit and care must be taken in setting the values 3 W
5. a vapor state As the saturated vapor condenses on the PC board surface the resulting evaporation heat provides the energy for reflow soldering Cooling coil Saturated vapor Heater After components are glued to the PC board surface the board assembly is transferred through a molten solder fountain with the component side facing down Then the components are soldered to the board Mounting pads on PC boards TI bed si di b9 b Screen Printing must be designed to abso Squeegee i i iy Paste solder placement errors while taking Ji i si abi es account of solderability and lv S Mask CLL Pa insulation Refer to the suggested mounting pad layout FMS i ae solder Dispenser in the application data for the i gt Air M Syringe _ required relay product postu ir Paste solder may be applied on or dispanser T Needle the board with screen printing or _r m rf pr 3 Pad board dispenser technigues For either method the paste solder must be coated to appropriate thickness and shapes to achieve good solder wetting and adequate insulation For small lightweight components such as chip components a self alignment effect can be expected if small placement errors exist However this effect is not as expected for electro mechanical components such as relays and they require precise positioning on their soldering pads If SMT relays are subjected to excessive mechanical stress from th
6. are made with the hole slightly larger than the lead wire so that the component may be inserted easily Also when soldering the solder will build up in an eyelet condition increasing the mounting strength The standard dimensions for the Hole diameter and Land are shown in the table below Standard dimensions for the Hole and Land diameter Unit mm inch 2 0 to 3 0 079 to 118 0 1 039 3 5 to 4 5 138 to 177 Remarks e The Hole diameter is made 0 2 to 0 5mm 008 to 020inch larger than the lead diameter However if the jet method wave type jet type of soldering is used solder may pass through to the component side Therefore it is more suitable to make the Hole diameter equal to the lead diameter 0 2mm The Land diameter should be 2 to 3 times the Hole diameter Do not put more than 1 lead in one hole Because copper clad laminates have a longitudinal and lateral direction the manner of punching fabrication and layout must be observed with care Expansion and shrinkage in the longitudinal direction due to heat is 1 15 to 1 2 of that in the lateral and accordingly after the punching fabrication the distortion in the longitudinal direction will be 1 15 to 1 2 of that in the lateral direction The mechanical strength in the longitudinal direction is 10 to 15 greater than that in the lateral direction Because of this difference between the longitudinal and lateral directions when products having long configurations are to b
7. level usage Contact c Contact material The rated life may become reduced when used at high d Life temperatures Life should be verified in the actual use e Contact resistance atmosphere Itis necessary to be tested and reviewed under actual use conditions with actual load and actual application Note that ambient temperature and applied voltage a Operate time cause the change of operate time and bounce time b Release time Note that operate time and release time do not include Operate time c Bounce time bounce time d Switching frequency Give consideration that switching life changes depending on switching frequency a Vibration resistance Give consideration to performance under vibration and b Shock resistance shock in the use location c Ambient use Confirm the allowable ambient temperature of the relay temperature d Life Selection can be made for connection method with a Breakdown voltage plug in type printed circuit board type soldering and b Mounting screw fastening type Other items Connection Selection of protection construction can be made for c Size PCB mounting method such as soldering and cleaning d Protection For use in an adverse atmosphere sealed construction construction type should be selected Are there any special conditions Mechanical characteristics various other damages such as unsuitable operation contact transfer welding abnormal wear increase in contact
8. please verify in actual installation and operational condition Vibration of the area where relay is installed may be enhanced more than expected depending on installation condition of PCB So please verify in actual use condition NO contact is the recommended contact for the use at the vibration frequent area because the vibration resistance performance of NC contact is generally inferior to that of NO contact It is ideal for mounting of relay that the movement of the contacts and movable parts is perpendicular to the direction of vibration or shock Especially note that the vibration and shock resistance of NC contacts while the coil is not excited is greatly affected by the mounting direction of the relay Condensation forms when vapors when there is a sudden change in temperature under high temperature high humidity conditions Note that condensation may cause deterioration of the insulation breaking of coil and rusting Note that if a relay is connected or installed with a high heat capacity such as bas bar connector harness and PCB heat removal phenomenon will accelerate cooling of the relay inside and promote condensation So please verify in actual installation condition 12 Usage ambient condition 13 Installation 14 PC board design 8 Water resistance 9 Freezing 10 Low temperature low humidity 1 Connector installation 1 PC board design consideration Select the sealed type for exposure
9. resistance Therefore please confirm that in actual use conditions such as actual circuit and actual load or contact our company 2 Inductive In the case of switching on and off with inductive loads such as coil magnet crutch and solenoid the arc load at switching can cause a severe damage on contacts and greatly shortening of life In addition in the case of switching at a high frequency a blue green corrosion may be developed So please contact our company to use it If the current in the inductive load is relatively small the arc discharge decomposes organic matter contained in the air and causes black deposits oxides carbides to develop on the contacts This may result in contact failure So please contact our company to use it 3 Lamp load Large inrush current enhancing contact welding will be impressed Its current value is greatly affected by wiring resistance switching frequency and ambient temperature The load current characteristics in actual circuit and actual use condition must be examined and sufficient margin of safety must be provided in selection of a relay It is dangerous to use a lamp load whose nominal current is small even a large nominal current has been tested beforehand Please contact us when switching at nominal current with a small lamp load 40W or less because 4 Load 1 General Contact performance is significantly influenced by voltage and current values applied to the contacts in Electrical life part
10. the power supply voltage Diode and zener diode circuit Contact Circuit Features Others lt is effective in the diode circuit when the release time is too long Use a zener diode with a zener voltage about the same as the power Devices Selection supply voltage In the actual circuit it is necessary to mount the protective device diode etc in the immediate vicinity of the load If it is mounted too far away the effectiveness of the protective device may diminish As a guide the distance should be within 50cm Devices Selection Inductive load Avoid using the protection circuits shown in the figures below Although it is usually more difficult to switch with DC inductive loads compared to resistive loads use of the proper protection circuit will raise the characteristics to that for resistive loads Contact Contact i Power C Power No good supply 3 No good Although it is extremely effective in arc Although it is extremely effective in arc suppression as the contacts open the suppression as the contacts open the contacts are susceptible to welding since contacts are susceptible to welding since energy is stored in C when the contacts open charging current flows to C when the and discharge current flows from C when the contacts close contacts close 4 Load 23 Connection Connect the load to one side of the power supply as shown in Fig a Connect the contacts to the other electrical of load side This prev
11. to water In the case of water exposure in severe conditions or immersion please verify water resistance of the relay or contact us Even for sealed type relays its terminals are not waterproof so please avoid a failure such as terminal corrosion Note that moisture adhered on relay in a due condensation or a high humidity condition freezes when the temperature is lower than 0 C This may cause problems such as sticking of movable parts or operational time lags or poor contact conduction Therefore please test them in actual use environment Note that if a relay is connected or installed with a high heat capacity such as bas bar connector harness and PCB heat removal phenomenon will accelerate cooling of the relay inside and promote freezing So please verify in actual installation condition The plastic becomes brittle if the relay is exposed to a low temperature low humidity environment for long periods of time Please consider the vibration at installation area to avoid loosely contact Also note that even a microscopic vibration may cause contact failure at the contact area of relay terminal and connector Decrease of fitting performance of connector may cause abnormal heat at connector contact area depending on use temperature and applying heat Sufficient margin of safety must be provided in selection of a connector Please select the proper material of connector and surface treatment to avoid corrosion at the contact area of r
12. Panasonic Automotive Relay Users Guide ASCT1F46E 2008 12 panasonic electric works net ac Panasonic Electric Works Obihiro Automotive Relay User s Guide Panasonic Electric Works Obihiro Co Ltd Oct 1 2008 1 Edition Please use the check sheet Confirmation 1 Confirmation The rated switching power and life mentioned in the specification and catalog are given only as guides A under the under the relay may encounter a variety of ambient conditions during actual use resulting in unexpected failure actual use actual use Therefore it is necessary for proper use of the relay to test and review with actual load and actual condition application under actual operating conditions Safety 1 Specification Use that exceeds the specification ranges such as the coil rating contact rating and switching life should precautions range be absolutely avoided Doing so may lead to abnormal heating smoke and fire 2 Installation Never touch live parts when power is applied to the relay Doing so may cause electrical shock When maintenance installing maintaining or troubleshooting a relay including connecting parts such as terminals and sockets be sure that the power is turned off 3 Connection When connecting terminals please follow the internal connection diagrams in the catalog to ensure that connections are done correctly Be warned that an incorrect connection may lead to unexpected operation error ab
13. Safe life is an inverse of degree of reliability It is given as value B which makes the following equation true 1 R B t In general B 1 R B 10 is more often used In some cases this represents a more practical value of reliability than MTTF 3 Failure 1 What is Failure Failure is defined as a state of system equipment or component in which part of all of its functions are impaired or lost 2 Bathtub Curve Product s failure rate throughout its lifetime is depicted as a bathtub curve as shown below Failure rate is high at the beginning and end of its service lifetime I II 111 Initial failure period The high failure rate in the initial failure period is derived from latent design errors process errors and many other causes This process is called debugging performing aging or screening in order to find out initial failures Accidental failure period The initial failure period is followed by a long period with low stable failure rate In this period called accidental failure period failures occurs at random along the time axis While zero accidental failure rate is desirable this is actually not practical in the real world Wear out failure period In the final stage of the product s service lifetime comes the wear out failure period in which the life of the product expires due to wear of fatigue Preventive maintenance is effective for this type of failure The timing of a relay s wear out failu
14. a higher temperature temperature atmosphere The resistance temperature coefficient of copper wire is about 0 4 for 1 C and the coil characteristic resistance increases with this ratio On the other hand coil resistance and the drop out voltage will decrease at lower temperature Coil resistance change decreases with the same ratio at higher temperature about 0 4 for 1 C Therefore please confirm the relay operation in every operating temperature range with attention to such temperature characteristic generated by a relay itself or other instruments causes increase of temperature inside the box 3 Applied Note that a coil impression with a voltage greater than or equal to the maximum continuous impressed voltage voltage may cause temperature rise which could cause coil burning or layer short Furthermore do not exceed the usable ambient temperature range listed in the catalog Please contact us regarding PWM control 5 Coil 4 Twin relay For relays which have multiple coils such as twin relay for forward reverse operation of motor if the coils impressed coil are continuously turned on at the same time the coil temperature may exceed the tolerance in a short voltage simultaneous time due to heat generation of each coil Please contact us before use operation 5 Continuous Coil heating due to continuous current applying to coil for extensive time periods will cause deterioration current in insulation performance for coil For
15. andard defines the degree of reliability as follows The probability at which a system equipment or part provides the specified functions over the intended duration under the specified conditions 2 MTBF MTBF is an acronym of Mean Time Between Failures It indicates the mean time period in which a system equipment or part operates normally between two incidences of repair MTBF only applies to repairable products MTBF tells how long a product can be used without the need for repair Sometimes MTBF is used to represent the service lifetime before failure 3 MTTF MTTF is an acronym of Mean Time To Failure It indicates the mean time period until a product becomes faulty MT TF normally applies to unrepairable products such as parts and materials The relay is one of such objective of MTTF 4 Failure Rate Failure rate includes mean failure rate and momentary failure rate Mean failure rate is defined as follows Mean failure rate Total failure count total operating hours In general failure rate refers to momentary failure rate This represents the probability at which a system equipment or part which has continued normal operation to a certain point of time becomes faulty in the subsequent specified time period Failure rate is often represented in the unit of percent hours For parts with low failure rates failure unit Fit 10 hour is often used instead of failure rate Percent count is normally used for relays 5 Safe Life
16. e placement machine s pickup head and damaged inside their performance cannot be guaranteed Our SMT relays are supplied in tube packaging compatible with automatic placement processes We also offer tape packaging at customer request 3 Reflow Reflow soldering under inadequate soldering conditions may result in unreliable relay performance or even physical damage to the relay even if the relay is of surface mount type with high heat resistance 1 IRS profile Ti 150 to 180 C 302 to 356 F t 60 to 120 sec T 230 C 446 F or more te Less than 30 sec Ta Less than 250 C 482 F Note When a soldering technigue other than above is to be used hot air hotplate laser or pulse heater technigue carefully investigate the suitability of the technigue The soldering temperature profile indicates the pad temperature In some cases the ambient temperature may be greatly increased Examine it under the specific mounting condition 2 Manual soldering Soldering iron tip temperature 350 C 662 F Soldering iron wattage 30 to 60 W Soldering time Less than 3 sec 3 Others For other solder methods except for the above such as hot air heating hot plate heating laser heating pulse heating etc please check for mounting and soldering condition before use e t is recommended that the soldered pad be immediately cooled to prevent thermal damage to the relay and its associated components e While surface mount
17. e fabricated the lengthwise direction of the configuration should be made in the longitudinal direction and PC boards having a connector section should be made with the connector along the longitudinal side The figure below Example As shown in the drawing below the 150mm 5 906 inch direction is taken in the longitudinal direction Direction r 150 5 906 T Longitudinal direction Also as shown in the drawing below when the pattern has a connector section the direction is taken as shown by the arrow in the longitudinal direction Longitudinal direction 15 PCB 1 Through hole type mounting In keeping with making devices compact it is becoming more common to solder the relay to a PC board along with the semiconductors instead of using the previous plug in type in which relays were plugged into sockets With this style loss of function may occur because of seepage into the relay of flux which is applied to the PC board Therefore the following precautions are provided for soldering a relay onto a PC board Please refer to them during installation in order to avoid problems The type of protective structure will determine suitability for automatic soldering or automatic cleaning Therefore please review the parts on construction and characteristics 1 Mounting of Relay 2 Flux Application 3 Preheating UUL e Avoid bending the terminals to make the relay self clinching Relay performance canno
18. ed from outside the relay combine to produce nitric acid This corrodes the internal metal parts and adversely affects operation Avoid using them at an ambient humidity of 85 RH or higher at 20 C If it is unavoidable to use them in such environment please consult us Plastic sealed type relays are especially not suited for use in environments which require airtight relays Although there is no problem if they are used at sea level avoid using them in atmospheric pressures beyond 96 10kPa Also avoid using them in an atmosphere containing flammable or explosive gases It is recommendable to use relays in a normal temperature and humidity with less dust sulfur gases SO2 H2S and organic gases Sealed types plastic sealed type should be considered for applications in an adverse environment Silicon based substances silicon rubber silicon oil silicon based coating material silicon caulking compound etc emit volatile silicon gas Note that when silicon is used near relay switching the contacts in the presence of its gas causes silicon to adhere to the contacts and may result in contact failure Therefore please use a substitute that is not silicon based Plastic also has air permeability so please avoid using them in a silicone atmosphere If relays are proximately installed each other or installed near highly magnetized parts such as motor and speaker the relay may change its operational characteristics or cause malfunction So
19. elay terminal and connector and increase of resistance at connecting area which may be caused depending on ambient environment 1 Cautions regarding Pattern Layout for Relays Since relays affect electronic circuits by generating noise the following points should be noted Keep relays away from semiconductor devices Design the pattern traces with the shortest length Place the surge absorber diode etc near the relay coil Avoid routing pattern traces susceptible to noise such as for audio signals underneath the relay coil section Avoid through holes in places which cannot be seen from the top e g at the base of the relay Solder flowing up through such a hole may cause damage such as a Sealing failure Even for the same circuit it is necessary to consider the pattern design in order to minimize the influence of the on off operations of the relay coil and lamp on other electronic circuits as shown in the figure below Diode bridge Diode bridge a Ly C ie __ Constant i Electronic Tr voltage Electronic Tr ations circuit circuit i ee Relay currents and electronic circuit Relay coil currents consist only of A1 and B1 currents flow together through A and B Electronic circuit currents consist only of A2 and B2 A simple design can change safety of the operation 14 PC board design 2 Hole and Land diameter 3 Expansion and shrinkage of copper clad laminates The Hole and Land diameter
20. en high voltage is applied to a twin relay Has hot start been considered p5 5 1 pag Is the ambient temperature within the range of use Also is the ambient p5 5 2 temperature characteristics considered Is the applied voltage below the maximum continuous applied voltage p5 5 3 Coil operation voltage Is there a risk of using PWM control PWM control requires careful p5 5 3 attention Er Doesn t coil of twin relay operate at the same time p6 5 4 mg Hasn t the current continuously applied to coil over a long period p6 5 5 In case of relay operation by electric circuit is the circuit designed in p6 6 1 p8 6 2 consideration of mal function transistor circuit other electric components on the circuit been considered Coil operation circuit Check sheet 2 2 Refer to the following Category el i Check item page and item on box Page Category Section ri Have precautions been checked in the case of switching with both high p9 7 1 and low loads by the same contact Bea Doesn t heat dissipation occur under low temperature p9 7 2 Has transient state of contact resistance been considered p9 8 1 Contact resistance Emi Are contact voltage and current 6V 1A or higher p9 8 2 5 TORET Eg Are there any problems regarding operating sound of relay p9 9 1 p9 9 2 Veika m Are there any problems regarding abnormal weak noise of relay p9 10 1 p9 10 2 noise Eg Is temperature humidity atomosphere pressure wit
21. ents high voltages from developing between contacts If contacts are connected to both life side of the power supply as shown in Fig b there is a risk of shorting of the power supply when relatively close contacts short b Bad example Regarding the following circuit constructions with 2 coil relays twin relays or single pole relays an arc between contacts may be generated when breaking of load current depending on the type of load current voltage and load Please note that or contact us lt 2 coil relay twin relay or two of single pole relays gt i l 4 B side OFF 1 gt 24 Short When using of multipole relays such as 2 coil relays twin relays verify insulation and breakdown between voltage between contacts in each pole in order to avoid an accident caused by short interelectrodes 5 Coil 1 Hot start After continuous applying of current to coil and contacts if the current is turned OFF then immediately impressed voltage turned ON again coil resistance and the pick up voltage will increase due to the temperature rise in the voltage coil Temperature rise value of coil is greatly affected by circuit board connected harness connected connector heat dissipation of system modules and heat source around relay Please verify whether it is operating properly or inoperative under actual vehicle and actual use conditions 2 Ambient Coil resistance and the pick up voltage will increase when the relay is used in
22. eriod at high temperatures or high humidity levels or in atmospheres with organic gas or sulfide gas sulfide film or oxide film may be formed on surface of the contacts which may cause contact instability contact failure and functional failure Please check the atmosphere in which the units are to be stored and transported 18 Product 1 Tube packing Some types of relays are supplied with tube packaging If you remove some relays from the tube be handling sure to slide a stop plug into one end of a tube to hold the remaining relays firmly and avoid rattling of relay inside the tube Note that rattling may cause a damage on appearance and or performance slide in the plug Do not use the relays if they were dropped or fallen down in a tube packing condition because there is a risk of characteristic failure Fall of tube 19 Reliability 1 What is Reliability 1 Reliability in a Narrow Sense of the Term In the industrial world reliability is an index of how long a particular product serves without failure during use period 2 Reliability in a Board Sense of the Term Every product has a finite service lifetime This means that no product can continue normal service infinitely When a product has broken down the user may throw it away or repair it The reliability of repairable products is recognized as reliability in a broad sense of the term For repairable products their serviceability or maintainability is another problem
23. hen there is chattering in the input signal because of waveform oscillation an CR time constant circuit should be inserted in the stage before the Schmitt trigger circuit However the response speed drops Signal g R 5 Avoid Darlington circuit connections High amplification Care must be taken in this circuit due to increase of Vcesar It does not cause a failure immediately but it may lead to troubles by using for a long period or by operating with many units Lt VCESAT Pi f Tre About 0 7V Sande 2 About 0 1 No good Darlington connection Good Emitter connection Due to excessive consumption of Tr2 conducts completely power heat is generated Tr1 is sufficient for signal use A strong Tr1 is necessary 6 Coil 1 Relay drive 6 Residual Coil Voltage impressed by means of In switching applications where a semiconducior transistor UJT etc is connected to the coil a residual circuit atransistor voltage is retained at the relay coil which may cause incomplete restoration and faulty operation Using of DC coils may cause incomplete restoration or reduction in contact pressure and vibration resistance because its drop out voltage is lower than that of AC coil 10 or more of the rated voltage also because there is a tendency to increase the life by lowering the drop out voltage When the signal from the transistor s collector is taken and used to drive another circuit as shown in the figure as fo
24. hin the range of use p10 12 1 Have precautions been checked in the case of switching under high p10 12 1 humidity E Is the ambient environment free from particles dusts sulfidizing gas p10 12 2 organic gas ss Is the ambient environment free from silicon p10 12 3 environmental i Is the ambient environment free from high field magnetic instruments p10 12 4 condition such as speaker Are the ambient vibration and shock below the relay s vibration and p10 12 5 p10 12 6 impact characteristics Also is there no resonance after the relay is Isn t there a risk of freezing and dewing of relay p9 7 2 p10 12 7 p 11 12 9 Isn t there a risk of water or oil adhesion p11 12 8 Doesn t vibration or shock cause poor connection between a relay anda p11 13 1 connector Have precautions been checked for operating of flux applying and p13 15 1 p15 15 2 automatic soldering Have precautions been checked for cleaning operation of print board p13 15 1 p15 15 2 Isn t glass shot performed for flux cleaning Particle of the glass may p13 15 1 p15 15 2 get inside the relay and cause operation failure relay teminal and changes the relay characteristics characteristics PCB mounting Soldering Any strong forces such as terminal clinch are not applied at attaching p18 16 3 Aren t load shock or vibration which is out of the allowable range p18 17 1 applied during transportation Storage Are temperature a
25. icle or by remaining current soon after a motor is turned off 21 Wire length If long wires a few ten meters are to be used in a relay contact circuit inrush current may become a problem due to the stray capacitance existing between wires In such case add a resistor in series with the contacts Equivalent circuit Contacts Oo a pl i Added resistor wire Ta capacitance 10 to 509 of wire 4 Load 22 Contact Use of contact protective devices or protection circuits can suppress the counter emf to a low level electrical life protective However note that incorrect use will result in an adverse effect Typical contact protection circuits are circuit given in the table below Also note that release time will slow down due to sneak in the circuit and may cause the electrical life to shorten and slight welding Contact Circuit Inductive load The diode connected in parallel causes the energy stored in the coil to flow to the coil in the form of current and dissipates it as joule Features Others heat at the resistance component of the inductive load This circuit delays the release time 2 to 5 times the release time listed in the catalog Use a diode with a reverse breakdown voltage at least 10 times the circuit voltage and a forward current at least as large as the load current or larger In electronic circuits where the circuit voltages are not so high a diode can be used with a reverse breakdown voltage of about 2 to 3 times
26. icular the voltage and current waveforms at the time of application and release the type of load frequency of switching ambient atmosphere contact switching speed and of bounce which lead the continuous ON failure may occur due to locking caused by contact transfer phenomenon when switching arc is locally concentrated 4 Electric lts load current tends to cause contact welding easily because its inrush current is larger than that of the discharge regular lamp load The load current characteristics in actual circuit and actual use condition must be lamp load examined and sufficient margin of safety must be provided in selection of a relay 5 LED lamp It is necessary to check the contact reliability because the load current of the LED load is very small load Please contact us before use 6 Other lamp Please contact us before use of new structured lamp except for halogen Electric discharge lamp and load LED 7 Motor load When using of NC contact side of 1C contact for the motor brake mechanical life might be affected by the brake current Therefore verify in actual use conditions with actual circuit Note that larger inductivity of motor may cause contact damage and transfer even the motor load current is same 8 Capacitor Note that its load current tends to cause contact welding and contact transfer easily because its inrush load current is generally large which has a small break current and a short time period to reach an inrush pea
27. ing down of release time 12 Usage ambient condition 1 Temperature humidity air pressure 4 Magnetism 5 Vibration 6 Shock 7 Dew condensation During usage storage or transportation avoid locations subject to direct sunlight and maintain normal temperature humidity and pressure conditions The allowable specifications for environments suitable for usage storage and transportation are given below 1 Temperature The allowable temperature range differs with each relay so refer to the relay s individual specifications In addition in the case of transporting and storing relays in a tube package the temperature may differ from the allowable range of the relay So please contact us for individual specifications 2 Humidity 5 to 85 R H 3 Pressure 86 to 106 kPa Furthermore the humidity range varies with the temperature So use relays within the range indicated in the graph below Humidity R H Tolerance range Avoid freezing when J Avoid used at temperatures condensation when lower than 0 C 52 F used at temperatures 4 higher than 0 C 32 F Vs 5 P777 40 QO 85 o Temperature C F o The allowable temperature range differs for each relay Be sure the usage ambient temperature does not exceed the value listed in the catalog When switching with a load which easily generates arc in high humidity environment the NO generated by the arc and the water absorb
28. k value Also inrush current value is influenced by wiring resistance Therefore the inrush current in actual circuit must be examined and sufficient margin of safety must be provided in selection of a relay 9 Resistance This load causes relatively less contact damage since its inrush current is not large Select a relay based load on the rating control capacity or contact us 10 Small If the switching current is small 2A or less contact reliability decreases since the contact surface is not electric cleaned by switching arc So please contact us for use current load 11 Load Electrical life may be affected by load polarity connecting to relay contacts So please verify them in polarity actual use polarity 12 Voltage Under a circuit which inrush current is applied to such as lamps and capacitors the moment the contact drop of is closed voltage drop to the coil return of relay or chattering may occur Note that it may remarkably power reduce the electrical life supply 4 Load 13 Load If the load voltage is high the arc energy which generated at contact switching increases which may Electrical voltage decrease the electrical life Therefore it is necessary to give consideration to the voltage which could life occur in actual use condition 14 Coil voltage If coil applied voltage gets higher the relay operate time gets faster However contact bounce gets also larger so that the electrical life may decrease
29. laced on copper pads pre coated with paste solder and the board assembly is heated to solder the components on the pads reflow soldering 2 Features and Effects Allows high density mounting Components can be installed on both sides of a board System downsizing Ceramic PC boards can be used Compatible with automatic placement by robots Drilling for lead holes is not required Overall cost reduction Compact system designs are possible due to high density mounting High heat resistance High reliability Anti gas measures The surface mount relay is realized with the following advanced technologies Heat resistance encapsulation technique Gas analysis Reliability assessment Precision molding technique for heat resistant materials 3 Examples of SMT Applications 1 Infrared Reflow Soldering IRS 2 Vapor Phase Soldering VPS 2 Cautions for installation 1 Paste Soldering JUUUU JUUUU 2 Relay mounting IRS is the most popular reflow soldering technology now available for surface mounting It uses a sheath heater or infrared lamp as its heat source PC board assemblies are continuously soldered as they are transferred through a tunnel furnace comprised of a preheating heating and cooling stages Preheat Heating Cooling stage stage stage l KtACCELE LILII With VPS technology PCB assemblies are carried through a special inactive solvent such as Fluorinert FC 70 that has been heated to
30. lder is the optimum method for e Please take caution with multi layer soldering boards Relay performance may Adjust the level of solder so that it does degrade due to the high thermal not overflow onto the top of the PC capacity of these boards board Keep the tip of the soldering iron Unless otherwise specified solder clean ae under the following conditions U depending on the type of relay Soldering Iron 30W to 60W Iron Tip Approx 350 C Approx 260 C 5 C Temperature Temperature 900 F 41 F Soldering Time Within approx 3 Within approx 6 seconds Idering Ti Soldering Time RER 5 Cooling Immediate air cooling is recommend to prevent deterioration of the relay and surrounding parts due of soldering heat Although environmentally the sealed type relay plastic sealed type etc can be cleaned avoid immersing the relay into cold liquid such as cleaning solvent and coating material immediately after soldering Doing so may deteriorate the sealing performance Do not clean dust cover type relays and flux resistant type relays by immersion Even if only the bottom surface of the PC board is cleaned e g with a brush careless cleaning may cause cleaning solvent to penetrate the relay Plastic sealed type relays can be cleaned by immersion Use an alcohol based cleaning solvent Use of other cleaning solvents e g Trichlene chloroethene thinner benzyl alcohol gasoline may damage the relay case Cleaning with the boiling
31. llows a minute dark current flows to the relay even if the transistor is off This may also cause the problems described above Connection to the next stage through collector lo dark current No good 2 Relay drive 1 Ordinary drive method by means of For SCR drive it is necessary to take particular care with regard to gate sensitivity and erroneous SCR operation due to noise let There is no problem even with more than 3 times the rated current Rex 1K ohms must be connected RC This is for prevention of switching error due to a sudden rise in the power source or to noise 2 Cautions regarding ON OFF control circuits when used for temperature control circuits or similar one Care must be taken because the electrical life suffers extreme shortening when the relay contacts close simultaneously with an AC single phase power source 1 When the relay is turned ON and OFF using a SCR the SCR serves as a half wave power source as it is and there are ample cases where the SCR is easily restored 2 In this manner the relay operation and restoration timing are easily synchronized with the power source frequency and the timing of the load switching also is easily synchronized 3 In case of the load for temperature control whose load is a high current load such as a heater some relays switch only peak values and some other relays switch only zero phase values as a phenomenon of this type of c
32. method is recommended Avoid ultrasonic cleaning on relays Use of ultrasonic cleaning may cause breaks in the coil or slight sticking of the contacts due to the ultrasonic energy Do not cut the terminals When terminals are cut breaking of coil wire and slight sticking of the contacts may occur due to vibration of the cutter If the PC board is to be coated to prevent the insulation of the PC board from deteriorating due to corrosive gases and high temperatures note the following Do not coat dust cover type relays and flux resistant type relays since the coating material may penetrate the relay and cause contact failure Or mount the relay after coating Depending on the type some coating materials may have an adverse affect on relays Furthermore some solvents e g xylene toluene MEK P A may damage the case or chemically dissolve the epoxy and break the seal Select coating materials carefully If the relay and all components e g ICs are to be coated be sure to carefully check the flexibility of the coating material The solder may peel off from thermal stress material type for Relays Good electrical insulation Epoxy base Good Although slightly difficult to apply does not affect relay contacts Urethane base Gare Good electrical insulation easy to apply Solvent may damage case Check before use m ili Silicon base No Good Silicon gas becomes the cause of contact failure Do not use the silicon base type
33. nd humidity within the allowable range p18 17 2 transportation Is the ambient atomosphere free from organic gas and sulfidizing gas p18 17 2 handling Aren t dropped or fallen tube packages used p18 18 1 Please contact Panasonic Electric Works Obihiro Co Ltd Automation Controls Business Unit MiHead Office 1048 Kadoma Kadoma shi Osaka 571 8686 Japan MT elephone 81 6 6908 1050 MiFacsimile 81 6 6908 5781 panasonic electric works net ac All Rights Reserved 2008 COPYRIGHT Panasonic Electric Works Co Ltd ASCT1F46E 200812 Specifications are subject to change without notice Printed in Japan
34. normal heating and fire 4 Fail safe If there is a possibility that adhesion contact failure or breaking of wire could endanger assets or human life please make sure that a fail safe system is equipped in the vehicle In order to use the relays properly the characteristics of the selected relay should be well known and the 3 Selection of 1 Selection relay type conditions of use of the relay should be investigated to determine whether they are matched to the environmental conditions and at the same time the coil specification contact specification and the ambient conditions for the relay that is actually used must be fully understood in advance In the table below please refer to a Summary of the consideration points regarding selection of relay a Rating Select relay with consideration for power source ripple b Pull in voltage Give sufficient consideration to ambient temperature current and for the coil temperature rise and hot start c Drop out voltage When used in conjunction with semiconductors careful Coil current with the voltage drop d Maximum continuous When starting up careful with the voltage drop impressed voltage current e Coil resistance f Temperature rise Note that the relay life is balanced with the life of the device the relay is used in a Contact arrangement Is the contact material matched to the type of load It is b Contact rating necessary to take care particularly with low
35. ontrol Depending upon the sensitivity and response speed of the relay 4 Accordingly it causes either an extremely long life or an extremely short life resulting in wide variation So it is necessary to take care with the initial device quality check 7 Contact reliability 8 Contact resistance 9 Operate noise 10 Mechanical noise 11 Electrical noise Load switch Installation condition Transient state Contact voltage current Coil applied voltage Operate noise at installation Abnormal noise Serge voltage When switching with a very small load after switching with a large load contact failure by small load switching may occur due to particles generated during switching of the contact with large load Please note that or contact us Note that if it is connected or installed with a high heat capacity such as bas bar connector harness and PCB heat removal phenomenon at low temperature will make relay terminals and contacts cool and condensate a small amount of organic gas inside the relay which may cause a contact failure So please contact us before use Contact resistance consists of dynamic and static contact resistance Contact resistance on the catalogue and the specifications refers to static contact resistance Dynamic contact resistance usually shows a large value due to just after the contact operation Please contact us if a stable contact
36. re can be predicted with a certain accuracy from the past record of uses The use of a relay is intended only in the accidental failure period and this period virtually represents the service lifetime of the relay Il II Failure rate Time 3 Weibull Analysis Weibull analysis is often used for classifying a product s failure patterns and to determine its lifetime Weibull distribution is expressed by the following equation f x m y e Vai where m Figure parameter amp Measurement parameter y Position parameter Weibull distribution can be adopted to the actual failure rate distribution if the three variables above are estimated Failure rate The Weibull probability chart is a simpler alternative of complex calculation formulas The chart provides the following advantages 1 The Weibull distribution has the closest proximity to the actual failure rate distribution 2 The Weibull probability chart is easy to use 3 Different types of failures can be identified on the chart The following describes the correlation with the bathtub curve The value of the parameter m represents the type of the failure 1 Whenm lt 1 Initial failures 2 Whenm 1 Accidental failures 3 Whenm gt 1 Wear out failures Product name Relay name Date O O o o Check sheet 1 2 Refer to the following Category ener Check item page and item on box Page Category Section Safety an Does the vehicle sys
37. relays are solvent washable do not immerse the relay in cold cleaning solvent immediately after soldering 4 Cooling Cleaning e While sealed type plastic sealed relays are solvent washable do not immerse the relay in cold cleaning solvent immediately after soldering e Use alcohol or an equivalent solvent for cleaning e Boiled cleaning is approved for surface mount relays Ultrasonic cleaning may cause coil damage or light contact sticking 16 Soldering 1 Solder Please use the flux resistant type or sealed type in the case of automatic soldering 2 Cleaning Please use the sealed type for cleaning Also use the alcohol type for cleaning liquid and avoid ultrasonic cleaning When cleaning a printed circuit board after soldering we recommend using alcohol type cleaning liquid Please avoid ultrasonic cleaning The ultrasonic energy may cause breaking of coil and sticking of contacts 3 Terminal clinch Avoid bending terminals for the relay of print circuit board since it may cause malfunction 17 Storage 1 Transportation Relay s functional damage may occur if strong vibration shock or heavy weight is applied to a relay transportation during transportation of a device in which a relay is installed Therefore please pack them in a way using shock absorbing material so that the allowable range for vibration and shock is not exceeded 2 Storage If the relay is stored for extended periods of time including transportation p
38. resistance is necessary soon after a relay is turned on Note that if the contact applied voltage is small at 6V or less and contact applied current is small at 1A or less contact resistance may become a larger value due to a small amount of film on a contact surface Mechanical relays produce an operational noise at operate and release time Note that if the coil applied voltage is higher at operate time the noise becomes larger It is necessary to test relays in actual installation condition because operate noise may become larger in the installation condition than with a relay by itself due to resonance and sympathetic vibrations of installation PCB and system module Note that if a large current is applied to the contact electromagnetic repulsion makes contact vibrate and produces an abnormal noise Please contact us if quietness is required Note that if an external vibration and shock are applied to a relay while the relay turns off a movable part of the relay may vibrate and produce a noise So please test in the actual use condition if quietness is required When the relay turns off serge voltage is generated from the coil This serge voltage can be reduced if a resistor is connected in parallel to the coil Likewise it can be reduced more if a diode instead of resistor is connected in parallel However please contact us or note that if a resistor or a diode is connected in parallel electrical life may be affected due to slow
39. such circuit types please consider the fail safe circuit design in case of contact failure or breaking of coil 6 Coil 1 Relay drive 1 Connection method impressed by means of Collector connection method is the most recommendable when the relay is driven by means of a circuit a transistor transistor To avoid troubles in use the rated voltage should always be impressed on the relay in the ON time and zero voltage be done in the OFF time Pe T I I r Ieee Good Collector connection Care Emitter connection Care Parallel connection This is the most common When the circumstances make As the power consumption of connection which operation is the use of this connection the entire circuit increases usually stable with unavoidable the voltage may not the relay voltage should be be completely impressed on the considered relay and the transistor would not conduct completely 2 Countermeasures for surge voltage of relay control transistor If the coil current is suddenly interrupted a sudden high voltage pulse is developed in the coil If this voltage exceeds the breakdown voltage of the transistor the transistor will be degraded and this will lead to damage It is absolutely necessary to connect a diode in the circuit as a means of preventing damage from the counter emf In case of DC relay connection of Diode is effective As suitable ratings for this diode the average rectified current should be equivalent to the coil current
40. t be guaranteed if the terminals are bent e Correctly make the PC board according to the given PC board pattern illustration e Tube packaging for automatic mounting is available depending on the type of relay Be sure that the relays don t rattle Interference may occur internally if the gripping force of the tab of the surface mounting machine is too great This could impair relay performance e Adjust the position of the PC board so that flux does not overflow onto the top of it This must be observed especially for dust cover type relays e Use rosin based non corrosive flux e f the PC board is pressed down into a flux soaked sponge as shown on the right the flux can easily penetrate a dust cover type relay Never use this method Note that if the PC board is pressed down hard enough flux may even penetrate a flux resistant type relay e Be sure to preheat before using automatic soldering For dust cover type relays and flux resistant type relays preheating acts to prevent the penetration of flux into the relay when soldering Solderability also improves e Preheat according to the following conditions ei 120 C 248 F or less P PCB solder surface Within approx 2 minute Bad example Bad example e Note that long exposure to high temperatures e g due to a malfunctioning unit may affect relay characteristics 4 Soldering Automatic Soldering Hand Soldering e Flow so
41. tem have a fail safe in case of a relay failure p1 1 1 p1 2 4 Has it been confirmed by testing under actual load actual circuit and p2 4 1 actual condition Have load type load current characteristic and current value been p2 4 2 4 9 checked Isn t the applied contact current too small Small current is likely to p2 4 10 decrease the contact reliability Has connecting load polarity been checked p2 4 11 Ai Is the load likely to cause instant voltage drop p2 4 12 Isn t the applied contact voltage too high High voltage decreases p3 4 13 electrical life Eg Isn t applied coil voltage too high High voltage affects electrical life p3 4 14 Eg Isn t short pulse applied to coil p3 4 15 Isn t the switching frequency too high even including at abnormality p3 4 16 Load Electrical life Eg Doesn t switching continue for a long time p3 4 17 T Does it switch under high temperature p3 4 18 Have precautions been checked for using of coil surge absorption p3 4 19 circuit ea Have you checked there is no sneak current or voltage to the relay coil p3 4 20 Eri Is there stray capacitance between lead wires p3 4 21 Ray Have precautions been checked for using of contact protective circuit p4 4 22 Bey Is there a risk of dead short in the power supply p5 4 23 r Is there a risk of short circuit in the power supply at load rejection p5 4 23 ey Is there a risk of insulation and breakdown voltage between contacts in p5 4 24 each pole wh
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