Automatic Turn off Relay

Per request the circuit today we have relay circuit. It is worth noting again that the diagram provides a time delay of about 0.5 seconds for every microfarad in the value of capacitor C1.

Automatic Turn off Relay Circuit Diagram

This permits delays of up to several minutes. If desired, the delay periods can be made variable by replacing resistor R2 with a fixed and variable resistor in series whose nominal values are approximately equal of the total value of R2 (680K).

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Electronic Temperature Controlled Relay

This temperature controlled relay circuit is a simple yet highly accurate thermal control circuit which can be used in applications where automatic temperature control is needed. The circuit switches a miniature relay ON or OFF according to the temperature detected by the single chip temperature sensor LM35DZ.

When the LM35DZ detects a temperature higher than the preset level (set by VR1), the relay is actuated. When the temperature falls below the preset temperature, relay is de-energized. The circuit can be powered by any DC 12V supply or battery (100mA min.)

Electronic Temperature-Controlled Relay Schematic

How it works?
The heart of the circuit is the LM35DZ temperature sensor which is factory-calibrated in the Celsius (or Centigrade) scale with a linear Degree->Volt conversion function. The output voltage (at pin 2) changes linearly with temperature from 0V (0oC) to 1000mV (100oC).

The preset (VR1) & resistor (R3) from a variable voltage divider which sets a reference voltage (Vref) form 0V ~ 1.62V. The op-amp (A2) buffers the reference voltage so as to avoid loading the divider network (VR1 & R3). The comparator (A1) compares the reference voltage Vref (set by VR1) with the output voltage of LM35DZ and decides whether to energize or de-energize the relay (LED1 ON or OFF respectively).

Components list:

IC1 : LM35DZ
IC2 : TL431
IC3 : LM358

LED1 – 3mm or 5mm LED

Q1 – General purpose PNP transistor ( A1015,…) with E-C-B pin-out)
D1, D2 — 1N4148
D3, D4 — 1N400x (x=2,,,,.7)

ZD1 — Zener diode, 13V, 400mW

Preset (trim pot) : 2.2K (Temperature set point)
R1 – 10K
R2 – 4.7M
R3 – 1.2K
R4 – 1K
R5 – 1K
R6 – 33Ω

C1 – 0.1 µF ceramic or mylar cap
C2 – 470 µF or 680 µF electrolytic cap. (16V min)
Miniature relay – DC12V DPDT, Coil = 400 Ω or higher

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Reducing Relay Power Consumption

Relays are often used as electrically controlled switches. Unlike transistors, their switch contacts are electrically isolated from the control input. On the other hand, the power dissipation in a relay coil may be unattractive for battery-operated applications. Adding an analogue switch lowers the dissipation, allowing the relay to operate at a lower voltage. The circuit diagram shows the principle. Power consumed by the relay coil equals V2/RCOIL. The circuit lowers this dissipation (after actuation) by applying less than the normal operating voltage of 5 V. Note that the voltage required to turn a relay on (pickup voltage)is usually greater than that to keep it on (dropout voltage).

Reducing Relay Power Consumption Circuit Diagram : 

In this respect the relay shown has specifications of 3.5 and 1.5 V respectively, yet the circuit allows it to operate from an intermediate supply voltage of 2.5 V. Table 1 compares the relay’s power dissipation with fixed operating voltages across it, and with the circuit shown here in place. The power savings are significant. When SW1 is closed, current flows through the relay coil, and C1 and C2 begin to charge. The relay remains inactive because the supply voltage is less than its pickup voltage. The RC time constants are such that C1 charges almost completely before the voltage across C2 reaches the logic threshold of the analogue switch inside the MAX4624 IC.

When C2 reaches that threshold, the on-chip switch connects C1 in series with the 2.5 V supply and the relay coil. This action causes the relay to be turned on because its coil voltage is then raised to 5 V, i.e., twice the supply voltage. As C1 discharges through the coil, the coil voltage drops back to 2.5 V minus the drop across D1. However, the relay remains on because the resultant voltage is still above the dropout level (1.5 V). Component values for this circuit depend on the relay characteristics and the supply voltage. The value of R1, which protects the analogue switch from the initial current surge through C1, should be sufficiently small to allow C1 to charge rapidly, but large enough to prevent the surge current from exceeding the specified peak current for the analogue switch.

The switch’s peak current (U1) is 400 mA, and the peak surge current is IPEAK = (VIN – VD1) / R1 + RON) where RON is the on-resistance of the analogue switch (typically 1.2 Ω). The value of C1 will depend on the relay characteristics and on the difference between VIN and the pickup voltage. Relays that need more turn-on time requires larger values for C1. The values for R2 and C2 are selected to allow C1 to charge almost completely before C2’s voltage reaches the logic threshold of the analogue switch. In this case, the time constant R2C2 is about seven times C1(R1 + RON). Larger time constants increase the delay between switch closure and relay activation. The switches in the MAX4624 are described as ‘guaranteed break before make’. The opposite function, ‘make-before break’ is available from the MAX4625. The full datasheets of these interesting ICs may be found at http://pdfserv.maxim-ic.com/arpdf/MAX4624-MAX4625.pdf

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Simple Relay Actuating Circuit with Millivolt Sensitivity

Common electromagnetic relays with coil voltage of 5V, 6V or 12V can operate power circuits in the range of 250 to 300 volts and up to 20A. The actuating current of these relays is in the range of 50 to 100 mA. In many applications, such as temperature-controlled equipment, energisation/de-energisation of 5V, 6V or 12V relays for ‘on’/‘off’ control of the load is to be achieved by a few millivolts.

Circuit diagram :

Simple Relay Actuating Circuit Diagram

Here is a simple relay actuating circuit that can be used to energise relays with a few millivolts as the input. As shown in the figure, the circuit is built around op-amp µA741(IC1) followed by an emitter follower using transistor 2N3440 (T1) and a few discrete components. You can change the sensitivity required (when the input is in millivolts range) to energise the relay by changing the value of resistors R1, R2 and R3. In all the cases, values of R4, R5 and R6 remain unchanged.

Resistor R8 is basically a current-limiting resistor used in series with the relay coil. This resistor is not required with a 12V, 200-ohm relay. This circuit can be used to drive 24V relays, by changing the supply voltage to ±18V. To get the best results, using preset VR1 adjust the offset at pin 4 of the op-amp to as low a value as possible.  The working of the circuit is simple. When a few millivolts (say, 200 mV) are applied at the input terminal shown in the diagram, the output of IC1 at pin 6 goes high and transistor T1 conducts to energise relay RL1. As a result, the load gets power supply through normally-open (N/O) contacts of the relay.

Assemble the circuit on a general-purpose PCB and enclose in a suitable cabinet. Connect the relay carefully so that the contact can handle the load current.

Do not use resistor R8 with 9V or 12V relays. In this case, connect the junction of the anode of D2 and the coil of the relay to ground.

Author : DR G.N. Acharya  - Copyright : EFY

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LM339-Low Voltage, High Current Time Delay

This circuit a LM339 quad voltage comparator is used to generate a time delay and control a high current output at low voltage. Approximatey 5 amps of current can be obtained using a couple fresh alkaline D batteries. Three of the comparators are wired in parallel to drive a medium power PNP transistor (2N2905 or similar) which in turn drives a high current NPN transistor (TIP35 or similar).

Circuit diagram :

Low Voltage, High Current Time Delay Circuit Diagram

The 4th comparator is used to generate a time delay after the normally closed switch is opened. Two resistors (36K and 62K) are used as a voltage divider which applies about two-thirds of the battery voltage to the (+) comparator input, or about 2 volts. The delay time after the switch is opened will be around one time constant using a 50uF capacitor and 100K variable resistor, or about (50u * 100K) = 5 seconds. The time can be reduced by adjusting the resistor to a lower value or using a smaller capacitor. Longer times can be obtained with a larger resistor or capacitor. To operate the circuit on higher voltages, the 10 ohm resistor should be increased proportionally, (4.5 volts = 15 ohms).

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Relay Coil Energy Saver

Some relays will become warm if they remain energized for some time. The circuit shown here will actuate the relay as before but then reduce the ‘hold’ current through the relay coil current by about 50%, thus considerably reducing the amount of heat dissipation and wasted power. The circuit is only suitable for relays that remain on for long periods.

 

Circuit diagram:

 

Relay Coil Energy Saver Circuit Diagram

 

The following equations will enable the circuit to be dimensioned for the relay on hand: R3 = 0.7 / I Charge time = 0.5 × R2 × C1 Where I is the relay coil current. After the relay has been switched off, a short delay should be allowed for the relay current to return to maximum so the relay can be energized again at full power. To make the delay as short as possible, keep C1 as small as possible. In practice, a minimum delay of about 5 seconds should be allowed but this is open to experimentation.

 

The action of C2 causes the full supply voltage to appear briefly across the relay coil, which helps to activate the relay as fast as possible. Via T2, a delay network consisting of C1 and R2 controls the relay coil current flowing through T1 and R3, effectively reducing it to half the ‘pull in’ current. Diode D2 discharges C1 when the control voltage is Low. Around one second will be needed to completely discharge C1. T2 shunts the bias current of T1 when the delay has elapsed.

 

Diode D1 helps to discharge C1 as quickly as possible. The relay shown in the circuit was specified at 12 V / 400 ohms. All component values for guidance only.

 

Author: Myo Min - Copyright: Elektor

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Low Voltage Cut-Out

This circuit will detect when the voltage of a 12v battery reaches a low level. This is to prevent deep-discharge or maybe to prevent a vehicle battery becoming discharged  to a point where it will not start a vehicle. This circuit is different to anything previously presented. It has HYSTERESIS. Hysteresis is a feature where the upper and lower detection-points are separated by a gap.

Circuit diagram :

Low Voltage Cut-Out Circuit Diagram

Normally,  the circuit will deactivate the relay when the voltage is 10v and when the load is removed. The battery voltage will rise slightly by as little as 50mV and turn the circuit ON again. This is called "Hunting." The off/on timing has been reduced by adding the 100u. But to prevent this totally from occurring, a 10R to 47R is placed in the emitter lead. The circuit will turn off at 10v but will not turn back on until 10.6v when a 33R is in the emitter. The value of this resistor and the turn-on and turn-off voltages will also depend on the resistance of the relay.

Author : Colin Michel - Copyright : 200 Transistor Circuits

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Solar Relay

With extended periods of bright sunshine and warm weather, even relatively large storage batteries in solar-power systems can become rather warm. Consequently, a circuit is usually connected in parallel with the storage battery to either connect a high-power shunt (in order to dissipate the excess solar power in the form of heat) or switch on a ventilation fan via a power FET, whenever the voltage rises above approximately 14.4 V. However, the latter option tends to oscillate, since switching on a powerful 12-V fan motor causes the voltage to drop below 14.4 V, causing the fan to be switched off.

In the absence of an external load, the battery voltage recovers quickly, the terminal voltage rises above 14.4 V again and the switching process starts once again, despite the built-in hysteresis. A solution to this problem is provided by the circuit shown here, which switches on the fan in response to the sweltering heat produced by the solar irradiation instead of an excessively high voltage at the battery terminals. Based on experience, the risk of battery overheating is only present in the summer between 2 and 6 pm. The intensity of the sunlight falling within the viewing angle of a suitably configured ‘sun probe’ is especially high precisely during this interval.

This is the operating principle of the solar relay. The trick to this apparently rather simple circuit consists of using a suitable combination of components. Instead of a power FET, it employs a special 12-V relay that can handle a large load in spite of its small size. This relay must have a coil resistance of at least 600 Ω, rather than the usual value of 100-200 Ω. This requirement can be met by several Schrack Components relays (available from, among others, Conrad Electronics). Here we have used the least expensive model, a type RYII 8-A printed circuit board relay. The light probe is connected in series with the relay. It consists of two BPW40 phototransistors wired in parallel.

Solar Relay Circuit Diagram

The type number refers to the 40-degree acceptance angle for incident light. In bright sunlight, the combined current generated by the two phototransistors is sufficient to cause the relay to engage, in this case without twitching. Every relay has a large hysteresis, so the fan connected via the a/b contacts will run for many minutes, or even until the probe no longer receives sufficient light. The NTC thermistor connected in series performs two functions. First, it compensates for changes in the resistance of the copper wire in the coil, which increases by approximately 4 percent for every 10 ºC increase in temperature, and second, it causes the relay to drop out earlier than it otherwise would (the relay only drops out at a coil voltage of 4 V).

Depending on the intended use, the 220-Ω resistance of the thermistor can be modified by connecting a 100-Ω resistor in series or a 470-Ω resistor in parallel. If the phototransistors are fastened with the axes of their incident-angle cones in parallel, the 40-degree incident angle corresponds to 2 pm with suitable solar orientation. If they are bent at a slight angle to each other, their incident angles overlap to cover a wider angle, such as 70 degrees. With the tested prototype circuit, the axes were oriented nearly parallel, and this fully met our demands. The automatic switch-off occurs quite abruptly, just like the switch-on, with no contact jitter.

This behaviour is also promoted by the NTC thermistor, since its temperature coefficient is opposite to that of the ‘PTC’ relay coil and approximately five times as large. This yields exactly the desired effect for energising and de-energising the relay: a large relay current for engagement and a small relay current for disengagement. Building the circuit is actually straightforward, but you must pay attention to one thing. The phototransistors resemble colourless LEDs, so there is a tendency to think that their ‘pinning’ is the same as that of LEDs, with the long lead being positive and the short lead negative. However, with the BPW40 the situation is exactly the opposite; the short lead is the collector lead. Naturally, the back-emf diode for the relay must also be connected with the right polarity. The residual current on cloudy days and at night is negligibly small.

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