Relays and Relay Devices
Relays and Relay Devices
www.hella.com/soe-electronics
2 | INTRO
INTRODUCTION 2
A small component with a big history. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
How HELLA checks and ensures quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTROMECHANICAL RELAYS 8
Explanation and uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Relay types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MINI RELAY 13
Mini relay – normally-open relay 12 V, with bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mini relay – normally-open relay 12 V, without bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Mini relay – normally-open relay 24 V, with bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Mini relay – normally-open relay 24 V, without bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Mini relay – change-over relay 12 V, with bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Mini relay – change-over relay 12 V, without bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Mini relay – change-over relay 24 V, with bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Mini relay – change-over relay 24 V, without bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
MICRO RELAY 24
Micro relay – normally open contact relay/changeover relay 12 V/24 V, without bracket. . . 24
TECHNICAL DATA 26
Technical data of the relays – Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Climatic and mechanical tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FLASHER UNITS 30
Explanation and uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Test circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Flasher Unit 6 V / 12 V, with bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Flasher Unit 12 V, without bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Flasher Unit 24 V, with bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Flasher unit 24 V, with bracket/without bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Flasher Unit 24 V, without bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
LED flasher unit 12 V / 24 V / 9 - 33 V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
LED lighting: Failure control and electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
The right solution for your vehicle electronics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
ACCESSORIES 56
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INTRO | 3
A small component with a big history
Relays have been used to remotely control circuits for over 180 years. The technology has proven
its reliability millions of times and is today still the first choice for many applications, such as in
automotive engineering.
From the telegraph to automotive engineering Quality relays from HELLA – versatile and reliable
➔ The relay owes its name to former times when mail was ➔ Manufacturing expertise:
still carried by horse. An den so genannten Relaisstationen HELLA produces more than 100 million units per year at
konnten die Postreiter ihre erschöpften Pferde gegen its own facilities – thanks to optimised production at an
ausgeruhte tauschen. Today, we call an electromagnetic, attractive price and with one of the lowest failure rates in
remotely operated switch a relay. the entire industry.
4 | INTRO
A small component with a big history
1972 Q-relay with plastic base plate, also available with built-in fuse
1976 S1-relay: replacement for Q-relay. Can be produced fully automatically, also available with built-in fuse
1989 Round connector relay: specially produced for Daimler AG, with plastic housing
2006 Intelligent flasher units for active LED flashers with current pulse evaluation in acc. with ISO 13207-1
2012 New and refined relay products with lower power consumption to help reduce CO2 emissions
INTRO | 5
6 | INTRO
How HELLA checks and ensures quality
■ Electrical parameters:
Within the context of product release, starting voltage,
dropout voltage, contact voltage drop, coil resistance and
Time (minutes)
insulation resistance are tested, for example. Accompanying
the manufacturing process, the electrical parameters are
recorded at the end of the production process by end-of-line
testers. These can be evaluated statistically. One important
factor for guaranteeing the consistent high quality of the
relays produced.
■ Analytical tests:
Here, the materials used and the different connecting
processes such as soldering and welding are tested.
1) Load curve, 20 A resistive 10 A 500 ms The tests are carried out randomly during incoming goods
testing and following production.
■ Certificates:
HELLA has been certified in a range of relevant areas e.g.
DIN EN ISO 9001:2008, ISO / TS 16949:2009, ISO 14001.
HELLA relays also comply with the ROHS (2002/95/EC) and
REACh standards.
INTRO | 7
Explanation and uses
Key
8 | ELECTROMECHANICAL RELAYS
Explanation and uses
Functional principle
Relays are basically electrically operated switches which use an electromagnet to move a switching
mechanism by switching one or more contacts. They are used where one or more load circuits need to be
switched on or off by means of a control signal. Characteristic of the electromechanical relay is the complete
(galvanic) isolation between the control and controlled circuits.
Make relays
Make relays are used to close an electric circuit between a power source and one or more electrical loads,
i.e. the loads are switched on. Relays are operated by means of switches, pulse generators or control
devices. Typical vehicle applications are headlamps, auxiliary headlamps as well as fog lamps, horns,
heaters, air conditioning systems and many other applications.
Fig. 2) The control circuit (86 / 85) is active and the current flow in the magnetic coil (copper wire) induces a
magnetic field, which pulls the armature down onto the magnetic core. The make contacts are closed and the
load circuit (30/87) is therefore also closed.
Change-over relays
Fig. 1
Change-over relays switch the load circuit over from one electrical load to another. These relays can be
operated by a dashboard switch, for example. Change-over relays are used for switch applications with two
stages/speeds such as heated rear windows or fan motors etc.
Rated voltage
ELEKTROMECHANICAL RELAYS | 9
Explanation and uses
Rated load
(depending on load type)
A ➔ Resistive load:
The current remains around the
same from switch-on to switch-off
(e.g. rear window heater).
➔ Inductive load:
The inrush current increases to the
rated current with a specific delay
time due to the build-up of the
inductor’s magnetic field and then
levels off (e.g. switching on a
solenoid switch). During switch-off, a
voltage of up to several thousand
volts is (theoretically) induced,
resulting in an electric arc between
the relay contacts just opened.
➔ Capacitive/bulb load:
The inrush current of a capacitive
load or a lamp can rise to ten times
the rated current before leveling off
to the rated current.
10 | ELECTROMECHANICAL RELAYS
Explanation and uses
Coil circuit
In order to prevent voltage spikes caused by mutual inductance when switching off the coil current,
our relays are in part equipped with resistors or diodes parallel to the coil.
The connections of the relays are each labelled with numbers. The corresponding assignment is enclosed.
ELEKTROMECHANICAL RELAYS | 11
Relay types
Mini relay
Mini relays according to ISO 7588-1, blade terminals according to ISO 8092-1.
Contact configurations: Normally open contact, changeover contact, max. 50 A rated
switching current (normally open contact), rated voltage: 12 V, 24 V
Areas of application include: headlights, starters, fuel pumps, fan motors, horns and
fanfares.
Micro relay
Micro relays according to ISO 7588-3 (1988), blade terminals according to ISO 8092-1.
Contact configurations: Normally open contact, changeover contact, max. 35 A rated
switching current (normally open contact), rated voltage: 12 V, 24 V
Areas of application include: fuel pumps, air conditioning systems, windshield
washer systems, wiper motors.
High-power relay
Mini relay version with enlarged dimensions, flat connector according to ISO 8092-1.
Contact configuration: Normally open contact, changeover contact, max. 60 A rated
switching current, rated voltage: 12 V, 24 V
Areas of application include: battery disconnect relays, starter motors, glow plugs,
ignitions, windshield heating.
12 | ELECTROMECHANICAL RELAYS
Mini relay – normally-open relay 12 V, with bracket
* At 80 °C ambient temperature / **packaging unit / *** In combination with mating connector 8JD 745 801-001/-011
18 | MINI RELAYS
Mini relay – change-over relay 12 V, with bracket
12 V
24 V
12 V
24 V
General specifications
Permissible ambient temperature -40 °C … +125 °C -40 °C … +85 °C -40 °C … +125 °C -40 °C … +85 °C -40 °C … +125 °C
Storage temperature -40 °C … +130 °C -40 °C … +125 °C -40 °C … +130 °C -40 °C … +125 °C -40 °C … +130 °C
Coil specifications
Rated voltage 12 V 12 V 24 V 24 V 12 V
Pick-up voltage at test temperature <8V <8V < 17 V < 15.6 V <8V
Drop-out voltage at test temperature <1V <1V > 3.5 V > 3.5 V > 1.3 V
Coil resistance at test temperature 85 / 100 Ohm 85/90 Ohm 305 / 315 Ohm 350 / 360 Ohm 100 Ohm
without parallel component ± 10 % ± 10 % ± 10 % ± 10 % ± 10 %
Insulation resistance
> 100 MOhm > 100 MOhm > 100 MOhm > 100 MOhm > 100 MOhm
Coil circuit/load circuit
Breakdown strength
> 1,000 VDC > 1,000 VDC > 1,000 VDC > 1,000 VDC > 1,000 VDC
Coil circuit/load circuit
Contact details
... normally open contact in new state < 10 mV/A < 10 mV/A < 10 mV/A < 10 mV/A < 5 mV/A
... break contact in new state < 10 mV/A < 15 mV/A < 10 mV/A < 15 mV/A –
... normally open contact after life endurance test < 10 mV/A < 15 mV/A < 10 mV/A < 15 mV/A < 10 mV/A
... break contact after life endurance test < 10 mV/A < 20 mV/A < 15 mV/A < 20 mV/A –
Mechanical lifetime
107 107 107 107 107
(number of switching operations)
26 | TECHNICAL DATA
Technical data of the relays – Overview
-40 °C … +85 °C -40 °C … +85 °C -40 °C … +125 °C -40 °C … +105 °C -40 °C … +125 °C -40 °C … +125 °C
-40 °C … +125 °C -40 °C … +125 °C -40 °C … +130 °C -40 °C … +125 °C -40 °C … +85 °C -40 °C … +150 °C
9.5 x 1.2 mm 9.5 x 1.2 mm 6.3 x 0.8 mm 6.3 x 0.8 mm 6.3 x 0.8 mm 6.3 x 0.8 mm
6.3 x 0.8 mm 6.3 x 0.8 mm 4.8 x 0.8 mm 4.8 x 0.8 mm 4.8 x 0.8 mm 6.3 x 0.8 mm
6.3 x 0.8 mm 6.3 x 0.8 mm 4.8 x 0.8 mm 4.8 x 0.8 mm 4.8 x 0.8 mm 6.3 x 0.8 mm
9.5 x 1.2 mm 9.5 x 1.2 mm 6.3 x 0.8 mm 6.3 x 0.8 mm 6.3 x 0.8 mm 6.3 x 0.8 mm
– – 4.8 x 0.8 mm 4.8 x 0.8 mm 4.8 x 0.8 mm –
12 V 24 V 12 V 12 V 24 V 12 V
8 V … 16 V 16 V … 30 V 8 V … 16 V 8 V … 16 V 16 V … 30 V 7 V … 18 V
> 100 MOhm > 100 MOhm > 20 MOhm > 100 MOhm > 100 MOhm –
> 1.000 VDC > 1.000 VDC > 500 VDC / VAC > 800 VDC > 500 VAC –
< 3 mV/A < 3 mV/A < 10 mV/A < 5 mV/A < 10 mV/A –
< 10 mV/A < 10 mV/A < 25 mV/A < 10 mV/A < 25 mV/A –
TECHNICAL DATA | 27
Climatic and mechanical tests
28 | TECHNICAL DATA
TECHNICAL DATA | 29
Explanation and uses
Key
Base plate
Power transistor
Capacitor
IC module
30 | FLASHER UNITS
Explanation and uses
Functional principle
➔ Each flasher unit is an astable multivibrator in the circuitry sense. Its role is to operate blinker lights
at the statutory frequency of 1.5 +/- 0.5 Hz or 90 +/- 30 rpm. This value applies to both directional and
hazard warning lights.
➔ Each flasher unit is assigned a separate output load or a permissible number of flashing indicator lights.
This specific load case variant may not be exceeded or undercut, as otherwise the failure control will fail
to work correctly. Some typical load cases which are supported are shown below:
2 x 21 W + 0 … 5 W 4 x 21 W + 2 x 5 W
Towcar + 1 trailer 2 + 1 x 21 W 6 x 21 W
2 + 1 x 21 W + 0 … 5 W 6 x 21 W + 2 x 5 W
3 + 1 x 21 W 8 x 21 W
Towcar + 2 trailers 2 + 1 + 1 x 21 W 8 x 21 W
In addition to the load cases above, there are other use cases which do not feature failure control. These variants can be found in the table
overview from page 44 on.
➔ The failure of an indicator light must be clearly displayed to the driver. The law permits failure control
by doubling the flashing frequency (E-control) or the indicator control lamp remaining off (P-control).
The failure control applies to motor vehicles and all trailers.
➔ For flashing circuits, it is common for different electric and control circuits to be split:
We distinguish between:
• Single-circuit flasher units
• Dual-circuit flasher units
• Pulse generators
➔ In addition to the above HELLA also offers pulse generators for flashing circuits. In principle, these are
flasher units without failure control. In contrast to the above-mentioned types, pulse generators can
already be operated with small loads (e.g. 10 W).
FLASHER UNITS | 31
Explanation and uses
Rated voltage
A ➔ The number of connected flashing indicator lamps must not exceed the use cases/rated loads
indicated for the respective flasher units
➔ Special-purpose variants available for LED lights
32 | FLASHER UNITS
Test circuits
15/30
C
Single-circuit units are used in load cases (per 21 W
bulb) 2x, 4x, 5x, 2+1, 3+1, 2+1+1 for passenger cars, 1,2 W
light commercial vehicles and tow vehicles. It is not C2
possible to distinguish between the failure of a lamp
on the towcar or on the trailer, as there is only one
1,2 W
measuring resistor for the load current. C3
1,2 W
31 49 a
C 1,2 W
C 1,2 W
21 W 21 W 21 W 5W 21 W 21 W 5W 21 W 21 W 21 W
15/30
21 W 21 W
21 W 21 W
21 W 21 W
FLASHER UNITS | 33
Flasher Unit 6 V / 12 V, with bracket
6V
12 V
* At room temperature and test voltage / ** Packaging unit / *** not permitted according to StVZO
34 | FLASHER UNITS
Flasher Unit 12 V, with bracket
12 / 24 V
12 V
24 V
* At room temperature and test voltage / ** Packaging unit / *** not permitted according to StVZO
38 | FLASHER UNITS
Flasher unit 24 V, with bracket/without bracket
12 V
24 V
9 – 33 V
In the ECE R48 area of application, it is necessary by law to HELLA recommends, as the best solution, detecting the
ensure failure control of LED lamps/LED headlamps in the electrical pulse directly in the car manufacturer's vehicle
vehicle's electrical system using suitable measures. The driver electrical system. It is merely necessary to integrate the check
must be made aware of the failure visually or acoustically in according to ISO 13207-1. This means that you no longer have
the vehicle. to rely on interim solutions and use direction indicator control
units.
Functional diagram
Bulb
LED
Output (W)
The flasher unit or the light control unit checks the output after 100 -130 ms for
an amplitude of approx. 21 W. The measurement is performed at this point.
LED and bulb have the same current consumption at this time, so a failure can be
clearly detected.
Single pulse
Representation of the power consumption of a bulb and of an LED lamp with integrated pulse Time (t)
42 | FLASHER UNITS
LED lighting: Failure control and electrical connection
All HELLA LED direction indicators with integrated electronics In the event of a defect in the lamp, which can occur even if a
for failure control run checks on themselves and generate a single LED fails, the above-mentioned impulse is not generated.
single pulse. This pulse is evaluated by the electronic ballasts. The ballasts switch off the bulb simulation and the flasher unit
The ballasts simulate a 21 W bulb. This makes operation with reports the defect to the driver. By measuring the lamp current
conventional flasher units possible. during the time window of 10 ms, it is possible to directly
compare the HELLA LED lamp and a bulb version.
If the vehicle manufacturer does not provide direction indicator failure control via the vehicle electrical system, HELLA
offers the following solutions:
HELLA provides electronic ballasts that make it possible to display the direction indicator failure for various vehicle assemblies and
modifications. This is necessary if the vehicle manufacturer does not guarantee direction indicator failure control via the vehicle's
electrical system:
FLASHER UNITS | 43
The right solution for your vehicle electronics
RETROFITTING/
EQUIPING Start Is a direction indicator relay installed in the vehicle? Yes
THE VEHICLE
No Switch on vehicle ignition and remove the bulb of a direction indicator lamp without
pressing the direction indicator switch.
RETROFITTING/EQUIPPING TRAILERS
Solution 1:
Light control unit with integrated check Solution 2:
of the failure pulse in accordance with LED flasher unit
ISO 13207-1
12 V 12 V 24 V
Vehicle manufacturers' light control units are able to check the Operating voltage 10 – 15 V 10.5 – 16 V 32 V
failure pulse in a standardised and unified manner in accordance
Operating temperature -40 to +85°C -40 to +85°C -40 to +85 °C
with ISO 13207-1.
Protection class IP 53 IP 53 IP 53
Therefore interim solutions 1 - 3 will not be necessary since (contacts (contacts (contacts underneath)
communication takes place directly with the direction indicator underneath) underneath)
lamps. HELLA recommends this solution.
LED flasher unit 3+1 – 3+1
(Since trailers do not currently have their own vehicle electrical 3 direction indicators on the 4DW 009 492-111 – 4DW 009 492-011
system, this solution must be integrated in the towing vehicle.) vehicle / towing vehicle
1 direction indicator lamp on
an optional trailer
One flasher unit is required per vehicle. Any possible combination of bulbs and HELLA LED
direction indicators is permitted: from a full package with bulbs through mixed versions right
up to a full package with LED lights. Bulbs or HELLA LED direction indicator lamps are also
permitted on trailers. 2SD 013 155-001
Failure control
Solution 3:
Using simulation device for cold check.
Two LED direction indicators per vehicle can be monitored with one simulation device (only one
simulation device can be used per vehicle).
Solution 4:
Using LED lamp control unit from HELLA with ISO pulse.
Solution 4:
Solution 3: LED lamp control unit
Simulation device for cold check Universal trailer solution, truck-independent, hazard warning
signal mode must be taken into consideration separately
12 V 24 V Basic / Premium
Operating voltage 10 – 15 V 18 – 32 V Operating temperature -40 to +50°C
Rated current 1.5 A 1.5 A Protection class IP 6K9K
Operating temperature -40 to +85°C -40 to +85 °C Basic control unit
Protection class IP 54 IP 54 12 V 5DS 227 488-001*
(contacts underneath) (contacts underneath)
24 V 5DS 227 488-101*
FLASHER UNITS | 45
Explanation and uses
Key
Base plate
Capacitor
PCB relay
Functional principle
The wash/wipe interval control unit essentially comprises a pulse generator with a fixed or variable pulse/
pause ratio. Every pulse with which the wipe/wash motor is controlled via a relay causes a one-off back-
and-forth movement of the windshield wipers. Depending on the design, the length of the wipe pause is
4 s to X s.
Similarly to flasher units, the timer is designed as an astable multivibrator in the wipe/wash interval control
unit. A failure control stage as required by the flasher system is not needed for the WWI control unit.
HELLA also offers headlamp cleaning equipment that sprays cleaning fluid onto the headlamp glazing at a
high pressure. Depending on the variant, the length of the spray varies between 0.4 s and 0.8 s.
Rated voltage
12 V
24 V
* Packaging unit
50 | WIPE/WASH INTERVAL CONTROL UNITS
Wipe-wash interval switch 12 V / 24 V
12 V
24 V
* Packaging unit
WIPE/WASH INTERVAL CONTROL UNITS | 51
Explanation and uses
Key
Base plate
PCB relay
Functional principle
HELLA also supplies time relays with neither pick-up nor drop-off delay. In this case, the output is activated
or switched on for a specific period of time.
The delay or turn-on time can be adjusted with a DIP switch and fine-tuned with a potentiometer.
If a more powerful relay is used, higher current strengths or different load types – e.g. inductive, capacitive /
lamps – can be easily activated.
Rated voltage
➔ Up to 20 A, make contact
A ➔ Up to 10 A, break contact
The connections of the relays are each labelled with numbers. The corresponding assignment is enclosed.
* Packaging unit
54 | TIME CONTROL UNITS
Time Control Unit 24 V
* Packaging unit
TIME CONTROL UNITS | 55
Overview
Female connector housing, 5-pole Blade terminal sleeves: 8JA 715 606-001
8KW 744 819-003, 10 pieces
8KW 701 235-…,
8KW 744 820-003
Female connector housing, 5-pole Blade terminal sleeve: 8JA 717 291-007
8KW 719 874-007 100 pieces
Female connector housing, 5-pin, Blade terminal sleeves: 8JD 733 767-107
mountable side by side 8KW 744 819-003, 5 pieces
8KW 701 235-…,
8KW 744 820-003,
8KW 733 815-003
Female connector housing, 5-pole Pin contacts already equipped 8JD 733 962-001
5 pieces
Female connector housing, 5-pole With pre-fitted cable assembly 8JD 745 801-001
1 pieces
Female connector housing, 5-pole Blade terminal sleeves: 8JD 745 801-011
8KW 863 904-003, 1 pieces
8KW 863 904-013
* Packaging unit
56 | ACCESSORIES
Overview
Female connector housing, 5-pole Flat receptacles are already assembled, therefore no 8JD 733 963-001
accessories are required. 5 pieces
Cable sachet housing, 9-pin, Blade terminal sleeves: 8JA 003 526-107
mountable side by side 8KW 744 819-003, 5 pieces
8KW 701 235-…,
8KW 744 820-003 8JA 003 526-108
50 pieces
Cable sachet housing, 9-pin, Blade terminal sleeves: 8JA 183 161-107
mountable side by side 8KW 744 819-003, 5 pieces
8KW 701 235-…,
8KW 744 820-003,
8KW 744 822-003
* Packaging unit
ACCESSORIES | 57
HELLA GmbH & Co. KGaA
Rixbecker Straße 75
59552 Lippstadt, Germany
Tel.: +49 2941 38-0
Fax: +49 2941 38-7133
Internet: www.hella.com
www.hella.com/soe-electronics