Application Note

Relay Contact Life

Relay contacts are available in a variety of metals and alloys, sizes and Because silver and silver alloys sulfidate, contact pressures must be great
styles. There is no such thing as a universal contact. The relay user enough to break through this film. (Controlled arcing will also be helpful
should select contact materials, ratings, and styles to meet, as precisely in that it burns off the sulfidation, and contact overtravel wipes away the
as possible, the requirements of a particular application. Failure to do so residue.) While such pressures have no appreciable effect on silver-
can result in contact problems and even early contact failure. cadmium contacts, they do result in increased material wear of fine silver
contacts. Also, an interface voltage of several tenths of a volt can result
For example, some contact materials require an arc to keep them free of with fine silver contacts because of the sulfide film. This film has been
sulfidation, oxidation, and contaminates. Such materials on contacts known to capture and imbed airborne dirt. Breaking through this film
used in a dry or low-level circuit can result in the contacts failing electrically generates electrical noise. Because of this, fine silver contacts are not
to close the circuit, even though they make physically. The contacts may used for low-level switching, such as audio circuits. Rather, fine silver
look clean, but this is deceiving. In reality, there is a very thin film of and silver alloy contacts are for use in circuits of 12 volts, 0.4 ampere, or
insulating sulfidation, oxidation or contaminates on the surface of the more.
contacts. This film must be removed for circuit continuity to be
established, and arcing can accomplish this. (For dry and low-level circuits, Gold-Flashed Silver
bifurcated contacts should be used.) For relays which must sit idle for long periods of time before initial
operation, sulfidation of silver contacts can result in an impregnable
Applications Considerations contact interface resistance. Instead of specifying silver contacts for
In some applications, the contacts may be subjected to punishing current such applications, gold-flashed silver contacts should be specified. Gold
surges which can drastically reduce their life. Consider an incandescent flashing on each contact results in minimal sulfidation, and provides good
lamp. A 40 watt, 120V AC lamp has a current rating of .33 ampere. The electrical make upon contact. Because gold has a low boiling temperature,
resistance of the filament when cold, however, is so low that initial inrush the flashing will burn off after just a few switch cycles if arc voltage and
current may be as much as 6 amps! To attempt to switch the 40 watt current is exceeded. The silver underlayment is then exposed, and may
lamp with, say 2 amp contacts will result in early contact failure. develop a sulfide film. Unless this situation can be tolerated, gold-flashed
contacts should not be subjected to arcing.
The same situation exists in motor and transformer applications, and in
applications where significant distributed line capacitance exists. During Gold Overlay
start-up, a motor can pull 600% or more of its running current. Thus, a 3 A common contact for use in dry-and low-level circuits is gold overlay.
amp motor may actually pull 18 amps or more during start-up. A contact The overlay is of sufficient thickness that it should not wear through to
rated at least 20 amps should be used. Additionally, when disconnected, the base metal unless subjected to arcing conditions.
a motor acts as a voltage generator as it slows to a stop. Depending on
the motor, it can feed back into the circuit voltages well in excess of Silver Nickel
rated line voltage. These voltages appearing across the separating Depending on the application, material transfer may be quite prevalent
contacts can cause a destructive arc to exist between the contacts, which with fine silver contacts. Typically, material tends to accumulate in the
can lead to early failure of the contacts. Because of this, it is desirable to center of one contact, while the loss of material on the other contact
suppress the arc. (Techniques for arc suppression are discussed later in leaves a hole, or “pit.” This pitting may cause premature contact failure.
this application note.) In such an application, it may be desirable to use fine grain silver contacts.
These contacts are alloyed with 0.15% nickel, which gives the contacts
Transformers can present an unusual trap for an unsuspecting relay user. a fine grain structure. As a result, material transfer is evenly distributed
When power is removed from a transformer, its core may contain across the entire surface of the contact and the contacts last longer.
remanent magnetism. If power is reapplied when voltage is of the same
polarity as that of the remanent magnetism, the core may go into Silver Cadmium Oxide
saturation during the first half-cycle of reapplied power. As a result, Silver cadmium oxide contacts have long been used for switching loads
inductance will be minimal and an inrush current of perhaps 1,000% that produce a high energy arc. Silver cadmium oxide contacts are less
may exist for a few cycles until the core comes out of saturation. Worse, electrically conductive than fine silver contacts, but have superior
if reapplied power occurs at or near zero voltage and the increasing voltage resistance to material transfer and material loss due to arcing. They do
aids remanent magnetism, the core and the air gap may saturate. An exhibit greater interface resistance between mated contacts, and also a
inrush of perhaps 4,000% or more may result! Also, as with motor slightly greater contact assembly heat rise. The minimum arc voltagerating
loads, when power is removed from a transformer, the transformer will of silver cadmium oxide is 10 volts and, like fine silver contacts, the silver
develop a counter voltage which can cause a destructive arc to exist in this alloy will oxidize and sulfidate. Therefore, an arc is necessary to
between separating contacts. keep these contacts clean.

Distributed line capacitance presents particular problems for relays and Silver Tin Indium Oxide
their contacts. This occurs when a relay is located a considerable distance Silver tin indium oxide contacts, although not readily available, exhibit
from the load to be switched. The instant the contacts close, distributed better resistance to arc erosion and welding than silver cadmium oxide
line capacitance charges before load current flows. This capacitance can contacts. They are even less electrically conductive, though, and are
appear as an initial short-circuit to the contacts, and can pull a current harder than silver cadmium oxide contacts. They have greater interface
well in excess of load current. Prior to selecting a relay to switch a circuit resistance between mating contacts and, therefore, a greater voltage
when distributed line capacitance may be significant, instantaneous inrush drop and heat rise. At the present time, silver tin indium oxide is more
current should be measured, and contacts selected accordingly. expensive than silver cadmium oxide, and many relay users limit its use
to applications such as incandescent lamp loads and capacitors where
Contact Materials there is a massive inrush current during contact bounce. For low and
medium power resistive and inductive loads, silver cadmium oxide is
Fine Silver still the most commonly used and is recommended by Siemens
Fine silver has the highest electrical and thermal properties of all metals. Electromechanical Components (SEC). For applications where it is
It is the best general purpose material available. However, it is affected believed that silver tin indium oxide should be used, contact SEC
by sulfidation. The rate of sulfidation indoors in a metropolitan area is applications engineering.
approximately 70 micrograms per square centimeter per day. This
sulfidation forms a film on the surface of the silver which increases contact Silver Copper Nickel
interface resistance. Silver copper nickel contacts are for use in high inrush DC applications

1
 Application Note

such as incandescent lamps and capacitive loads. These contacts exhibit are exceeded. However, there will be no arc if load current at a given
good resistance to welding. minimum arc voltage is less than the minimum arc current for that voltage.
Likewise, there will be no arc if load voltage (or counter emf) is less than
Gold Silver Nickel Alloy the minimum arc voltage of the contact metal.
Gold silver nickel alloy contacts are for use in switching loads generally As stated, an arc may be necessary in order to burn off the contacts any
of less than one ampere, and are characterized by less electrical noise sulfidation, oxidation or contaminates. However, by its very nature, an
on make and break than fine silver contacts. Gold diffused silver contacts arc is destructive. For maximum contact life, the arc should be suppressed
offer characteristics similar to gold silver nickel alloy, but are less as quickly as possible as soon as it ignites. Such arc suppression may
expensive. be accomplished using techniques presented in this application note.

Palladium At voltage and current values of less than those required to ignite an arc,
Palladium contacts do not sulfidate or oxidize, and so offer extremely a spark may occur between separating contacts. This spark is a capacitive
low electrical noise levels. They have an electrical life expectancy of discharge, and is weak compared with an arc. Even so, the spark may
approximately 10 times that of fine silver contacts. However, because be sufficient to keep sulfidation, oxidation, and contaminates from building
of relatively poor conductivity properties, load currents are limited to up on the contacts. (Note: arc suppression has little, if any, effect on
about 5 amperes. contact sparking.)

Palladium contacts require .006” to .012” overtravel to insure good wiping Contact life is terminated when the contacts stick or weld, or when
action. Because of this, they are used primarily on telephone-type relays— excessive material is lost from one or both contacts and a good electrical
that is, relays on which the contact arms are parallel to the length of the make is not possible. These conditions are the result of cumulative
coil, and on which such overtravel is easy to obtain. Also, palladium material transfer during successive switching operations, and of material
contacts should be bifurcated to help insure circuit continuity on contact loss due to splattering.
closure.
Material Transfer and Material Loss
Tungsten Material transfer occurs as a result of I2R heat. As switch contacts begin
Tungsten contacts are for use in high voltage applications, usually where to separate, the area of contact diminishes. Load current flowing through
highly repetitive switching is required. Tungsten has a melting this increasingly constricted area generates heat which causes the contact
temperature of 3,380oC which gives it excellent arc-erosion resistance. material to melt, then boil. The liquified metal tends to collect on the
cathode contact because that contact is cooler than the anode contact.
Tungsten may develop troublesome oxide films, especially when used Material transfer also occurs during arcing. However, under this condition,
as the anode contact in some DC applications. Therefore, tungsten is material transfer is from cathode to anode—the amount of transfer being
often used as the cathode contact, and a palladium alloy used as the dependent on the severity and duration of the arc, and the type of contact
anode contact. Such a combination also minimizes contact interface material used. Because contact material migrates first one way, then
resistance and material transfer. the other, the ideal arc suppression technique would be to quench the
arc just as the anode recovers all of the material lost to the cathode just
Mercury prior to the arc striking. However, this is impractical even to attempt.
Mercury has a melting temperature of -38.87oC. Thus, as used in relays,
it is in a liquid state. Mercury will cling to the surface of any clean metal, Material loss is due primarily to splattering of the molten and boiling
and is used as the contacts in mercury-wetted reed relays. It has good metal as contacts bounce on make. Such loss can be significant over
electrical conductivity and, being liquid, there is no material transfer build- the course of tens of thousands of operations, and the only practical
up from contact to contact. Any such material transfer is negated by the way to minimize it is by arc suppression. Arc suppression quickly
fact that when the contacts open and the mercury returns to the pool in quenches the arc, thereby holding contact temperatures lower.
the bottom of the relay, fresh mercury takes its place at the very next
switch operation. Mercury has a boiling temperature of 357oC. Because In DC applications, metal migration is predictable in that one contact is
of this, mercury contacts cannot switch currents of more than a few always negative, and the other, positive. In AC applications where
amperes. switching is at random, either contact may be negative or positive when
arcing occurs. Migration will not be in the same direction each time the
Contact Life switch opens, and material loss from either contact should not be
significant—unless load conditions cause splattering.
The electrical life expectancy of general purpose and power relays is
generally rated to be 100,000 operations minimum, while mechanical Not all AC applications incorporate random switching, however. In some
life expectancy may be one million, 10, or even 100 million operations. applications, the relay is operated at a set rate or frequency. In such
instances, the contacts break load current at the same approximate point
The reason electrical life is rated so low compared with mechanical life on the sine wave. That is, the same contact is always positive, and the
is because contact life is application dependent. The electrical rating other negative at the instant of contact separation. Material transfer
applies to contacts switching their rated loads. When a set of contacts during arcing will always be in the same direction. In such applications,
switches a load of less than rated value, contact life may be significantly contact arc suppression may be necessary.
greater. For example, 25 amp, 240V AC, 80% P.F. contacts may be
expected to switch such a 25 amp load in excess of 100,000 operations. This is not to say that arc suppression is not needed on random-switching
If these contacts are used to switch, say, a 5 amp, 120V AC resistive AC applications. On the contrary, arc suppression can help control the
load, however, life may be in excess of a million operations. loss of contact material due to splattering of the molten metal. That is,
Rated electrical life also takes into consideration arc destruction of the when the arc is suppressed, contact temperature is held to a minimum.
contacts. By use of appropriate arc suppression, contact life may be
lengthened. Table 1 lists some arc voltage and current values for several Controlled arcing of short duration can be beneficial in actually achieving
different metals. An arc will ignite if both minimum arc voltage and current the rated life of the contacts. As stated, this is because such arcing
burns off of the contacts any deposits that might prevent electrical make.
Table 1 - Such control is achieved by arc suppression. Unless arcing and/or contact
Characteristics of Various Contact Materials overtravel cleans the contacts, films may develop on the contact surfaces,
Electrical or foreign matter may collect. For this reason, it is best to apply general
Conductivity Melt Arc Arc purpose and power relays only in applications where load voltage (or
Material %IACS Voltage Voltage Current counter emf) and current is in excess of the arc voltage and current
Cadmium 24 10 0.5 ratings of those contacts.
Copper 100 0.43 13 0.43
Gold 77 0.43 15 0.38 Contact Protection
Nickel 25 0.65 14 0.5
Palladium 16 0.57 15 0.5 Perhaps the most popular method of quenching an arc between
Silver, fine 105 0.37 12 0.4 separating contacts is with an R-C network placed directly across the
Tungsten 31 0.75 15 1.0 contacts. As the contacts just begin to separate and an arc ignites, load

2
 Application Note

current feeding the arc will be shunted into the capacitor through the To determine discharge di/dt:
series resistance, depriving the arc of some of its energy. As a result,
arc duration will be shortened and material loss will be minimized. dv 28 x .63
i = C = 1 x 10-6 = 8.8Aavg/ msec.
dt 2.0 x 10-6
Contact Protection Diagram where; .63 is the capacitor voltage loss during one time constant
of 2.0 msec.

This di/dt isn’t very severe and a wide variety of capacitors should be
able to withstand it. However, the di/dt of a 5 ampere 240 volt AC
application would be 107A/ msec. at peak of the AC line—that is, 340
volts; and capacitor selection* should be made accordingly.

Of course, di/dt may be lowered by a larger value of resistance to limit

Theoretically, the ideal arc suppression method would simply be a capacitor discharge current even more. But, the greater the value of
capacitor placed directly across the contacts. However, with no resistor resistance, the less effect the capacitor has on the arc.
in the circuit, when the contacts make, there is nothing to limit
capacitordischarge current. This nearly instantaneous discharge current Other Arc Suppression Methods
can generate a brief, but severe arc that may cause welded contacts,
depending on contact material and characteristics. Thus, the resistor is For quenching DC arcs in certain applications, relays are available that
necessary to limit capacitor discharge current. However, there is one have a permanent magnet located in close proximity to the contacts.
drawback. That is, the resistor tends to isolate the capacitor from the The magnet repels the DC arc, thereby stretching the arc and causing it
very contacts the capacitor is supposed to protect. Because of this, the to extinguish quickly.
amount of resistance should be kept as small as possible.
Some relay users connect a diode across the inductive load to prevent
Many relay users are unfamiliar with the selection of a capacitor for arc countervoltage from reaching the contacts. When the relay contacts
quenching service. To begin with, AC differs from DC in that AC crosses open, the storedenergy of the inductance recirculates through the diode,
zero 120 times per second for 60 Hertz service while DC, of course, is not through the arc. While this is an acceptable method of protecting the
continuous current. In AC service, the capacitor need not be as large as contacts, it does result in lengthened hold-up time of the inductive load.
in DC service because the AC arc will extinguish at a zero crossover For those applications that cannot tolerate lengthened hold-up time, a
point. In DC service, the capacitor must continue to shunt load current resistor may be placed in series with the diode. The resistor does,
sway from the contacts until the contacts separate far enough apart for however, lessen the effectiveness of the diode and, usually, a compromise
the arc to extinguish. must be reached by trial and error.

Capacitor Selection By using a zener diode in place of the resistor, hold-up time is greatly
Assume a DC application of 28 volts, 5 amperes. Further assume an reduced. This is because the diodes cannot turn on until the voltage
R-C network is needed that will result in contact voltage of perhaps 15 across them equals the sum of their voltage drops.
volts 1 msec. after the contacts have separated. Since the value of
resistance should be as small as possible, a 2 ohm resistor might be In some circuits, space is at a premium and there may not be sufficient
chosen. At 2 ohms, peak capacitor discharge current will be 14 amperes room for a zener and a regular diode. In such circuits, some designers
at time zero. Depending on contact material and size, this 14 amperes use a metal oxide varistor. The MOV performs in a manner similar to
may be quite acceptable for such a short period of time. back-to-back zener diodes. And, since the MOV is a bidirectional device,
it can be used in both AC and DC circuits.
Conact voltage—that is, arc voltage—at any given instant of time is simply
the sum of the voltage drop of the resistor and the capacitor voltage. An added benefit of arc suppression is the minimization of EMI. An
Select a capacitor voltage of, say, 10 volts. The remaining 18 volts must unsuppressed arc between contacts is an excellent noise generator. Such
appear across the 5.6 ohm load and the 2 ohm resistor. Thus, noise can be troublesome to sensitive components in a circuit, or within
instantaneous capacitor current is: the RFI field. In worst-case conditions, EMI can cause unwanted turn-
on of IC logic gates, SCRs, and triacs, and can cause damage to other
I = E = 18V = 2.4 ampere, semiconductor devices.
R 7.6Ω
and the voltage drop of the 2 ohm resistor is 4.8 volts. Arc voltage, *Suggested capacitor atypes are metalized foil and film foil. Check capacitor specifications for
therefore, one microsecond after contact separation is 4.8V + 10V = dv/dt and di/dt ratings.
14.8V, or about 53% of supply voltage.
Application Notes
To determine the size of capacitance needed, the basic equation for • Measure the current inrush of the circuit to be switched before
capacitor voltage may be used: specifying the relay.
• Never parallel relay contacts to double the contact rating.
ec = E(1 - ε -t/RC) Unless the relays are specially adjusted, they will not pick up
and drop out simultaneously. Even if they were to be specially
Rearranging the equation to solve for capacitance gives 1.1 mfd. adjusted, they would not hold this adjustment over life.
• Paralleling Form C contacts may result in an unwanted make-
c = -t = 1.1 x 10-6 farad before-break arrangement.
[In (1-ec)]R • Contacts rated low level to 2 amps may be used to switch a 2
E amp load. Once having done so, however, they cannot be
Where: t = 1 msec. used to switch reliably a low level load.
ec = 10 volts = capacitor voltage at time t. • In a circuit comprising a series of open relay contacts (AND
E = 28 volts (for AC, use peak value). logic), all but the last set of contacts to close will be dry.
R = 2.0 ohms. Likewise, in a circuit comprising a series of closed contacts,
all but the first to open will be dry.
The next question concerns capacitor construction. Can the capacitor • The use of many relay contacts in series may be limited by
withstand discharge surge currents? When the contacts close, the total circuit contact resistance.
capacitor will discharge through the resistor. For a 1 mfd. capacitor and • A “low level” circuit that pulls a capacitive inrush current or
a 2 ohm resistance, the time constant is: R x C = 2 x 1 mfd. = 2.0 develops an inductive counter emf is not low level. Worst
msec. case circuit conditions dictate contact rating, not steady state
conditions.

Tyco Electronics Corporation – P&B, Winston-Salem, NC 27102

Technical Support Center: 1-800-522-6752, www.pandbrelays.com
Specifications and availability subject to change without notice.
13C3236 Printed U.S.A. IH/12-00 3