Siemens Micromaster 420: Troubleshooting Faults and Alarms
A blog we posted earlier this week about the Micromaster 420 troubleshooting referenced the Faults and Alarms list for the Micromaster series, so we decided that it would make sense to make the list of Micromaster 420 Faults and Alarms directly available. This is from the corresponding manual for the Micromaster 420 series, but it is buried within the manual which most people most likely don’t even have. Hopefully, this helps with your troubleshooting of Siemens drive fault codes and alarms.
If you’re looking to purchase a Siemens Micromaster drive, view our 420 Micromaster Drives in stock. For more information or to request a quote, please call 800-691-8511 or email sales@mroelectric.com. We also provide pre-priced Micromaster 420 Repairs.
For the longest time, automation has always been the end-goal process when it comes to industrialization. That is that the user can quickly and efficiently complete a process repeatedly. Whether that process involves production or maintenance, the last two decades have seen a monumental rise in digitalization across numerous industries. Of course, digitalization is not a stranger to the world of automation machinery (and it would be incorrect to conflate that one is the opposite of the other). As it stands, all of the major industrial companies have some form of proprietary software that they use to automate their machinery and it’s been that way for several decades. However, in research done by Forrester, 77% of businesses today still rely on a paper process, with only 63% still using spreadsheet programs. Ultimately, this makes it more difficult to keep up with customer demands, and really wanting for a more streamlined process.
Automation and Digitalization
What is Automation?
Automation physically performs a process without the constant need of a human operator. Its tasks are dedicated by a group of rules preset by an operator usually in the form of either script commands or more robust software pending on what the task is.
What is Digitalization?
Digitalization is basically the process of taking a hard copy of something and converting it into a digital format. This could be anything from a worded manual or even a photo. Digitalizing is crucial to automation because it is how an automated process interprets data to commit to a function. The last few decades have seen a progression in the control of industrial automation from manual to digital.
The Possibilities
One example of how digitalization can streamline automation is through the way tasks and functions are being given to a piece of industrial equipment. For the longest time, equipment like automoted robots in manufacturing have been relying on external devices like PLCs (Programmable Logic Controllers) to output individual commands. These are all multiple components linked together on a bus and then connected to the drive and other components. This is the current setup for a lot of industrial and manufacturing operations.
While this setup does get the job done, it does present a few issues.
For starters, communication is one of the most important things when automizing. When multiple components come into play, there is always the chance of communication issues between devices. This can be attributed to various issues, like conflicting software between the devices or even simply how something is connected. There is also the issue of troubleshooting and trying to figure out the cause of an existing issue. With digitalization, instead of having a bunch of devices trying to talk to one another, there can be just one fully-integrated device using a single software. Having instant diagnostics would also cut down on troubleshooting time.
A Little Thing Called BIM
One piece of digitalization that could potentially change the way automation works is actually a technology that is becoming more prominent in the field of architecture and engineering called BIM (Building Information Modeling). What is BIM? In short, BIM is a digitalized way to create and manage data in the design, construction, and operation of products. Often it is used by architects, engineers, and construction working on sophisticated buildings. It allows for multiple teams to collaborate in real-time as they are working on a project. The same technology could virtually model the layout of a factory and could share accurate data in real-time across multiple teams.
Imagine an entire manufacturing setup being represented by a virtual model that is constantly sharing diagnostics of the equipment. If something were to break down or get faulty, the diagnostic could alert the technician, and using the virtual model, they can get a better visual representation of what is causing the issue and where it can be found. Simultaneously an alert can be sent out across different departments so that different teams can quickly communicate and come up with solutions to the problem. This in turn saves time on labor and the cost of troubleshooting.
Final Thoughts
Automation has always been and continues to be the end goal for many companies across multiple industries. With digitalization allowing for the process to function more autonomous than ever, it seems we are moving further along into a world of unfettered interconnectivity. As the digitalization of automation continues to progress, the acknowledgment of anxiety over its effects on human employees cannot be ignored. If everything is fully automated and more streamlined, what place does the employee have?
One issue that we need to consider is how automation will affect socioeconomics. From an optimistic point of view, one could argue that the present automation has already done away with a lot of the ‘human element’, and the margins of laying off workers would be small, especially when a company could train up employees to learn the technology.
On the other hand, we’re talking about a situation where only a handful of positions are available. Often, a company would rather onboard someone who already has experience rather than train an existing employee. Automation could pessimistically mean that both low-skilled and specialized employees both have a hard time finding work. On one end when most of the general tasks can be automated why would a company need to hire humans? Not to mention that exists a ceiling with just how many specialized jobs exist versus how many specialized employees compete to fill those seats. This is an existing issue we can see across multiple tech sector positions today.
What the solution is, remains to be seen. While the advancement of automation is crucial to productivity, it is something that should be treated cautiously in regards to how it affects the working person.
With no ceiling in sight for the climbing gas prices around the nation, many Americans are forced to adjust both their driving and spending habits to keep pace. Plus, with the holiday season in full swing, Americans need to account for higher airfare, food costs, and hotel prices as they plan their vacations, which may mean trips closer to home. Gone are the days of purchasing gas for under $2.00 per gallon. We now live in an era, where the price per gallon exceeds the federal minimum wage in certain locations––talk about pain at the pump.
Minimum wage workers and low-income commuters are suffering the most as a large percentage of their paychecks are being ravaged by rising gas prices. In California, a 12-gallon tank of gas costs minimum wage workers in some areas nearly 57% of a day’s pay. In some states like Pennsylvania and Utah, gas prices continue to rise, while minimum wage still sits at $7.25 an hour––where it’s sat for the last ten years, despite growing inflation rates.
To uncover where soaring gas prices are taking the biggest bite out of workers’ paychecks, MRO compared the minimum wage to the mean gas price in 100 U.S. cities. We dug deeper, focusing on 18 cities where gas costs over 80% of a minimum wage employee’s paycheck, ushering in a dystopian-like society all over the U.S. Read on to see where your city and state stack up.
What Causes Gas Prices to Go Up?
Low prices at the pump in our pre-pandemic world weren’t just a fever dream. If you remember, the demand for oil drastically fell during the pandemic as the world shut down and people were forced to stay home, but as the U.S. slowly started to recover, the demand for oil rebounded once more. The only problem? Oil production came to a grinding halt and drilling new oil wells takes a lot longer than ordering a new outfit through Amazon Prime. Plus, inflated energy prices, transportation costs, and a U.S. ban on purchasing oil from Russia all factor into soaring oil costs.
Why Is the Minimum Wage so Low?
The minimum wage was last raised thirteen years ago to $7.25 per hour on July 24, 2009, and it’s no secret that this amount has not kept up with inflation. Certain places like New York City have taken steps to raise the minimum wage for fast food workers to $15.00 per hour, but not every state and city has followed suit, leaving many wondering how they can survive and stretch their paychecks.
The minimum wage is indexed in 18 states and adjusts to keep up with inflation, but even this can vary depending on the individual counties within the same state. While President Biden did use executive order privileges to raise the minimum wage to $15.00 per hour for federal workers, republican and democratic lawmakers still can’t reach a resolution that satisfies either party’s agenda. With other pressing matters coming to a head, it’s not clear when or if a raised minimum wage that accounts for the rising cost of living will ever be ratified into law in the near future.
Can Minimum Wage Workers Afford the Gas Prices for Their Commute?
According to study results, minimum wage workers who make $5.15 per hour in Atlanta, GA pay $3.80 on average for a gallon of gas, resulting in 110.6% of a day’s paycheck being eaten by a full tank of gas (12 gallons). If the average commute in the U.S. requires 1.28 gallons of gas, then these Atlanta workers would lose wages just by showing up to work.
A full tank of gas consumes 93.1% of a day’s pay in cities like Boise City, ID, and it isn’t much better in places like Salt Lake City, UT, where 92.3% of a hard earned day’s wages is budgeted towards a full tank of gas. Those in Philadelphia, PAlose out on 85.9% of their paycheck towards a full tank. Minimum wage workers are stuck in a catch-22, but certain restaurant owners in Philadelphia are promising to raise their hourly wage to $15 per hour, creating light at the end of the tunnel.
Some customers are willing to pay higher menu prices to accommodate a living wage, and with the City of Brotherly Love welcoming 36.2 million visitors in 2021 alone, let’s hope this hot spot tourist destination can back these restaurant owners’ selfless initiatives.
Out of the top 18 cities where gas costs over 80% of a minimum wage worker’s paycheck, Pennsylvania holds five of those seats in places like Scranton (87.3% of a day’s pay), Pittsburgh (86.9% of a day’s pay), Harrisburg (86.4% of a day’s pay), and Allentown (85.5% of a day’s pay). The oil refinery explosion that occurred in South Philly in 2019 has forced the state to rely on imports more than ever before, contributing to the rising cost of gas.
Popular tourist destinations like New Orleans, LA, and Memphis, TN, are seeing skyrocketing gas prices at the pump. New Orleans minimum wage workers sacrifice 81.7% of a day’s pay to a gallon of gas while Memphis workers follow closely behind at 81.0%. Taking a trip to day drink at New Orleans’ historic bars? Avoid soaring gas prices and careen around the city on foot or with their bike share program.
The 5 States With the Largest Difference Between Minimum Wage and Average Gas Prices
Washington
Next, we found the five states with the largest difference between minimum wage and average gas prices. Topping the list is Washington state. With a minimum wage of $14.49 and the average price per gallon of gas at $4.23, minimum wage workers in Spokane, WA can purchase 3.43 gallons of gas with one hour of work. Minimum wage workers in Seattle, WA can purchase 3.00 gallons of gas with one hour of work. What’s more, a full tank of gas (12 gallons) costs minimum wage workers in Seattle, WA 50.1% of their pay that day.
Massachusetts
With a minimum wage of $14.25 and the average price per gallon of gas at $4.12, minimum wage workers in Boston, MA can purchase 3.46 gallons of gas with one hour of work. Additionally, a full tank of gas costs minimum wage workers in Boston, MA over 43% of a day’s pay.
Connecticut
In Connecticut’s capital, Hartford, minimum wage workers can purchase 3.40 gallons of gas with one hour of work. In New Haven, CT, home of Yale University, that number drops to 3.35 gallons. Therefore, a full tank of gas costs minimum wage workers in Hartford and New Haven nearly 45% of a day’s pay.
New York
With a minimum wage of $13.20 and the average price per gallon of gas at $4.27, minimum wage workers in Rochester, New York can purchase 3.09 gallons of gas with one hour of work. Minimum wage workers in Buffalo, NY, and Albany, NY could purchase 3.13 and 3.17 gallons of gas, respectively.
Maryland
In Baltimore, MD, minimum wage workers can purchase 3.41 gallons of gas with one hour of work. Additionally, a full tank of gas costs minimum wage workers in Baltimore almost 44% of their pay that day.
Are There Any Signs of Relief on the Horizon for Minimum Wage Employees?
While minimum wage workers protest all over the country to get their voices heard, they still face an upward battle in this ongoing fight, despite there being a majority of Americans who are in favor of raising the minimum wage to $15.00 per hour. Governors in certain places like Pennsylvania are putting pressure on the General Assembly for a living wage and relief for their constituents. One survey found that while Republicans do agree the minimum wage should be increased, most would prefer raising it to $11.00 per hour, instead of $15.00. As states, cities, and local counties possess the authority to raise the minimum wage, this fight may need to be taken to the lower levels of power, instead of advocating for a living wage on a national scale, where it may find less success.
Gas Prices and Stagnant Minimum Wages Continue to Affect Consumers
That wraps up our study, comparing gas prices to minimum wage amounts around the U.S. Gas prices continue to be a dire issue across the country in 2022, as well as a harrowing expense for lower-income Americans who are also struggling to keep up with rising food prices and housing costs.
While MRO Electric can’t control the cost of gas, we can offer the parts and equipment you need to keep things getting from A to B. Get in touch with us today by emailing sales@mroelectric.com or calling us at 800-691-8511 for a quote.
Research Methodology
Using data from the U.S. Department of Labor and GasBuddy, we collected the minimum wage in each state and the mean gas price in 100 U.S. cities in April 2022. We divided the minimum wage in each state by the average gas price in each city to determine how much gas a minimum wage worker can purchase with one hour of work. For all minimum wage amounts by state, we collected the basic minimum rate per hour, as listed by the Department of Labor. Gas prices are always fluctuating, so prices may differ from the time frame the data was pulled.
These multi-drive Control Units increase axis count and functionality. They have an Ethernet port, as well as more I/O and controller to controller communication. Each unit can manage up to 6 servo or vector axes in a high performance system. For standard systems, up to 12 V/Hz axes can be controlled from one CU320-2 unit. These Control Units significantly reduce system costs, as they increase functionality for positioning, safety integration, and drive control allowing all these functions to be controlled by one unit versus several.
Siemens CU320 control units also provide additional flexibility with a high number of programming options and digital inputs. With up to 12 binary inputs, the modules’ high I/O count add ease of use. The additional Ethernet port expands programming options as well. Overall, the CU320-2 control units allow for simple yet flexible performance with minimal cost and space requirements.
If you want to learn more about these high-performance drives, check out our blog on Sinamics s120 fault codes.
CU320-2 DP Module
The CU320-2 DP is a Sinamics Control Unit with a Profibus interface. It is a central Control Module in which the closed-loop and open-loop functions are implemented for one or more Line Modules and/or Motor Modules. It can be used with firmware version 4.3 or greater. It has 12 digital inputs, 8 digital inputs/outputs, 4 DRIVE-CLiQ interfaces, a Profibus and Ethernet interface, a serial interface (RS232), an option slot, and 3 measuring sockets.
MRO Electric stocks new and refurbished CU320-2 DP Control Units, which is part number 6SL3040-1MA00-0AA0. If you would like a replacement module, please call 800-691-8511 or email sales@mroelectric.com.
CU320-2 PN Module
The CU320-2 PN is a Sinamics S120 Control Unit without a Profibus interface. It has the same interfaces as described above, however without the Profibus port. It is also a central control unit with closed-loop and open-loop functions that can be implemented for one or more Line or Motor modules.
MRO Electric stocks new and refurbished CU320-2 PN Control Units, which is part number 6SL3040-1MA01-0AA0. If you would like a replacement module, please call 800-691-8511 or email sales@mroelectric.com.
It is important to understand the differences between faults and alarms on Sinamics S120 Drives by Siemens. We have included a list of common faults and alarm codes for S120 drives, what they mean, likely causes and how to fix the fault or alarm. For more Sinamics S120 faults and alarms, check out Part II and Part III of the series that we will be posting shortly. Be sure to check out our website to browse all of our Siemens products.
Understanding Faults
Sinamics S120 Fault Codes Numerical Ranges
When operating Sinamics S120, various errors can arise that may impact the machine’s performance. These faults are typically accompanied by error messages. The fault codes for Sinamics S120 are organized into numerical ranges, each corresponding to a specific type of issue:
F0001 – F0099: Control unit
F0100 – F0199: Reserved
F0200 – F0299: Power supply
F0300 – F0399: Feed unit
F0400 – F0499: Drive
F0500 – F0599: Option board
F0600 – F2999: Reserved
F3000 – F3099: DRIVE-CLiQ component power section
F3100 – F3199: DRIVE-CLiQ component encoder 1
F3200 – F3299: DRIVE-CLiQ component encoder 2
F3300 – F3399: DRIVE-CLiQ component encoder 3
F3400 – F3499: Reserved
F3500 – F3599: Terminal Module 31
F3600 – F4999: Reserved
F5000 – F5039: Communication Board (COMM BOARD)
F5040 – F65535: Reserved
This classification aids in swiftly identifying the type of problem based on the fault code range, making troubleshooting more efficient.
What happens when a fault occurs?
The appropriate fault reaction is initiated
Status signal ZSW1.3 is set.
The fault is entered in the fault buffer.
How are faults eliminated?
Remove the original cause of the fault
Acknowledge the fault
Understanding Alarms
What happens when an alarm occurs?
Status signal ZSW1.7 is set.
Alarms are “Self Acknowledging” meaning they are reset when the cause of the alarm has been eliminated.
List of Sinamics S120 Faults and Alarms
F01000: Internal software error
Message Value: Module: %1, Line: %2 Drive Object:All Objects Reaction: OFF2 Acknowledge: POWER ON Cause: An internal software error has occurred. Fault value (r0949, interpret hexadecimal) Remedy:
Evaluate fault buffer
Carry out a POWER ON (power on/off) for all components.
If required, check the data on the non-volatile memory (memory card).
Message Value: %1 Drive Object:All objects Reaction: OFF2 Acknowledge: POWER ON Cause:An exception occurred during an operation with the FloatingPoint data type. The error may be caused by the basic system or the OA application (e.g. FBLOCKS, DCC). Remedy:
Carry out a POWER ON (power on/off) for all components.
Check configuration and signals of the blocks in FBLOCKS.
Carry out a POWER ON (power on/off) for all components.
Upgrade firmware to a later version.
Contact Service Hotline.
F01003: Acknowledgement delay when accessing the memory
Message Value: %1 Drive Object:All objects Reaction:OFF2 Acknowledge:IMMEDIATELY Cause: A memory area was accessed that does not return a “READY”. Remedy:
Carry out a POWER ON (power on/off) for all components.
Contact Service Hotline
N01004 (F, A): Internal software error
Message Value:%1 Drive Object:All objects Reaction:NONE Acknowledge:NONE Cause:An internal software error has occurred. Remedy:Read out diagnostics parameter (r9999). Reaction upon F: OFF2 Acknowl. upon F: POWER ON Reaction upon A: NONE Acknowl. upon A: NONE
F01005: Firmware download for DRIVE-CLiQ component unsuccessful
Message Value: Component number: %1, fault cause: %2 Drive Object:All objects Reaction: NONE Acknowledge:IMMEDIATELY Cause:It was not possible to download the firmware to a DRIVE-CLiQ component Remedy:
Check the selected component number
Check the DRIVE-CLiQ connection
Save suitable firmware file for download in “/siemens/sinamics/code/sac/”
Use a component with a suitable hardware version
After POWER ON has been carried out again for the DRIVE-CLiQ component, download the firmware again. Depending on p7826, the firmware will be automatically downloaded.
A01006: Firmware update for DRIVE-CLiQ component required
Message Value: Component number: %1 Drive Object: All objects Reaction:NONE Acknowledge:NONE Cause: The firmware of a DRIVE-CLiQ component must be updated as there is no suitable firmware or firmware version in the component for operation with the Control Unit. Alarm value (r2124, interpret decimal): Component number of the DRIVE-CLiQ component Remedy:
Firmware update using the commissioning software:
The firmware version of all of the components on the “Version overview” page can be read in the Project Navigator under “Configuration” of the associated drive unit and an appropriate firmware update can be carried out.
Firmware update via parameter:
Take the component number from the alarm value and enter into p7828.
Start the firmware download with p7829 = 1.
A01007: POWER ON for DRIVE-CLiQ component required
Message Value: Component number: %1 Drive Object:All objects Reaction:NONE Acknowledge:NONE Cause: A DRIVE-CLiQ component must be powered up again (POWER ON) (e.g. due to a firmware update).
Alarm value (r2124, interpret decimal): Component number of the DRIVE-CLiQ component. If the component number is 1, a POWER ON of the Control Unit is required. Remedy:
Switch off the power supply of the specified DRIVE-CLiQ component and switch it on again.
For SINUMERIK, auto commissioning is prevented. In this case, a POWER ON is required for all components and the auto commissioning must be restarted.
A01009 (N): CU: Control module overtemperature
Message Value: – Drive Object:All objects Reaction: NONE Acknowledge:NONE Cause: The temperature (r0037[0]) of the control module (Control Unit) has exceeded the specified limit value. Remedy:
Check the air intake for the Control Unit.
Check the Control Unit fan.
MRO Electric and Supply carries new and used Sinamics modules. For more information or to request a quote, call 800-691-8511 or email sales@mroelectric.com.
Dealing with Sinamics S120 Fault Codes?
Fault codes on your Sinamics S120 can be a major setback. MRO Electric provides the expertise and parts you need to diagnose and resolve issues swiftly, ensuring your drive system runs smoothly without extended downtime.
Updated August 2019: You can purchase KUKA products, including KUKA arms, directly from our website.
MRO Electric and Supply distributes a variety of new and refurbished KUKA Robot arms.
We repaint and rebuild all of our refurbished KUKA arms, as well as purge and replace the grease according to the manufacturer’s specifications.
KUKA Robot Arm Models
We supply KUKA arms and wrists from a number of robots. We have included some popular KUKA robot models in our inventory below:
KR30
KR60
KR90
KR150
KR180
KR360
KR500
Any Many More!
About KUKA Robotic Arms
Most KUKA robotic arms are made up of 4-6 joints, and can be used for many different applications such as welding, material handling, material removal, and more. Because KUKA arms are so large, they are typically used to lift heavy payloads and are sometimes run by hydraulic and pneumatic methods. Most KUKA robot arms are made from aluminum and built from the base up, ending with the wrist and whichever end effect is needed to help the arm perform its given application.
KUKA was one of the first companies to use aluminum in robot arm design, which makes KUKA arm manipulators one of the fastest and lightest on the market. They also introduced a horizontal balancing spring on axis 2 before the other robot manufacturers, a design that has now been widely adopted.
Even if you are new to programming, you can explore different intuitive programming options to find out what will work best for you. KUKA robotic arms can be programmed in multiple ways including using KUKA’s own robot language, through hand guiding, a handheld probe, graphical offline programming and more.
MRO Electric and Supply has a warehouse full of many types of KUKA arms and wrists. Give us a call today if you need a replacement and we can usually ship you one same-day! You can also email sales@mroelectric.com for a quote.
Relays are an often overlooked, but pivotal component in modern technology, serving as the silent orchestrators behind a wide range of electronic operations. Whether controlling high-power machinery or everyday devices, relays play a crucial role in transferring signals and power without direct electrical connections. They are used across a wide range of devices and applications, from industrial automation to consumer electronics, and understanding how they work is key to fully utilizing their capabilities
Essentially, electrical relays control one electrical circuit by opening and closing contacts in another circuit. When a relay contact is normally open (NO), the circuit is open when the relay is not energized. Conversely, when a relay contact is normally closed (NC), the circuit is closed when the relay is not energized. Applying electrical current to the relay changes the state of these contacts, thereby controlling the connected circuit.
What Is a Relay?
A relay is an electrically controlled switch that has the ability to turn a circuit on or off. Depending on the application relays can do a number of things. Relays can be used as electrical switches to turn things on and off, or as amplifiers to convert smaller currents into larger ones. They can also be used to control a circuit with a low power signal or when multiple circuits need to be controlled by a single signal.
There are two kinds of relays, electromechanical and solid state. In this post, we will be focusing on electromechanical relays and how they work.
Why Are Relays Important?
Electrical relays are crucial because they enable the control of high-current loads using a small amount of electrical current. Relays apply voltage to the coil, which causes a low current to flow through it. This allows a larger current to pass through the contacts and control the electrical load. Relays are essential for applications where low-power control signals need to command high-power circuits.
What Are the Parts of a Relay?
Armature– is a basic metal piece that is balanced on a pivot or a stand. It is considered the moving ‘arm’ of the relay. It makes or breaks the connection with the contacts connected to it.
Spring– is connected to one end of the armature and pushes the armature back into place if no current is passing through.
Electromagnet– is a metal wire wrapped around a metal core. The wire does not have magnetic property but can be converted into a magnet with the help of an electrical signal.
Yoke– is a small metal piece affixedon a core which attracts and holds the armature when the coil is energized.
Contacts– conductive material that exists within the device whose physical contact opens or closes a circuit
A break refers to the number of locations on a circuit that a switch can make or break the flow of current. In electromechanical relays, there can be single breaks and double breaks. A single break is usually used with low power devices while a double break is usually used with high power devices.
A pole refers to the number of circuits that relays can pass through a switch. A single pole contact carries current through one circuit, while a double can carry it through two.
A throw refers to the number of separate wiring paths. For example, a triple throw switch can be connected to one of three contacts instead of one.
In an electromechanical relay, a small circuit has the ability to switch a larger circuit on or off through contacts by using an electromagnet. Some contacts come in different configurations depending on the use of the relay, namely, normally open relays and normally closed relays.
With a normally open (NO) relay, contacts are open when there is no current passing through. Once power is presented, the electromagnet will be activated. When charged, the electromagnet creates a magnetic field that attracts the armature and closes the contacts.
With a normally closed (NC) relay, contacts are closed when there is no current passing through. Unlike normally open relays, when normally closed relays become activated, the circuit will open and cause the current to stop flowing.
What Are the Different Types of Relays?
Electromechanical relays can be broken down into the following distinct categories: general purpose relays, machine control relays and reed relays.
General Purpose Relays
General purpose relays are electromechanical switches that typically function via a magnetic coil. Using an AC or DC current, general purpose relays often run at voltages such as 12V, 24V, 48V, 120V and 230V. Additionally, they can command currents ranging from 2A-30A. These relays are sought after due to them having a multitude of switch configurations and being cost-effective.
Machine Control Relays
Like general purpose relays, machine control relays are operated by a magnetic coil. Typically used to controlstarters and other industrial elements, these relays are robust. While this gives them greater durability, it also means that they are less economical than general purpose relays. However, with additional accessories and functionality, they have an advantage over general purpose relays.
Reed Relays
Reed relays consist of two reeds, which can open or close when controlled by an electromagnet. These small relays can operate up to eight reed switches, which are typically found inside of the electromagnetic coil. When the magnetic force is removed, the reeds return to their initial open position. Since the reeds are only a short distance apart from each other, reed relays work rather quickly. There are many benefits of using a reed relay, as their hermetic seal prevents the passage of contaminants. Additionally, this seal enables reed relays to have dependable switching.
There are many things to consider when choosing a relay for a project. Lifespan, operating environment, mechanical loads, size, and number and type of contacts are all important factors in choosing the right relay.
What Are the Pros and Cons of Using Relays?
While electromechanical relays have a variety of uses, different applications require different automation devices, and electromechanical relays may not always be the best fit. To help you determine if an electromechanical relay will work for you, we have highlighted some of the advantages and disadvantages below.
Advantages
Fast operation and reset
More definitive ON/OFF
Simple and most reliable
Disadvantages
Suffers the effects of age
No directional features
Needs a large amount of input power to operate
What Is a Relay Used For? Relay Applications
Relays protect electrical systems by preventing and reducing the damage to the connected equipment from over currents and voltages. Relays protect a wide range of equipment by detecting and isolating faults in a power transmission and distribution system.
Since electrical relays can control a high-voltage circuit using a low-voltage signal, they can help prevent damage to valuable electronics and components, including modems, amplifiers, and even the starter in your car.
Other applications for relays include:
Automotive
Appliances
Lighting systems
Telecommunication components
Industrial controllers
Electrical power protection systems
Traffic control
How Do You Test a Relay?
While relays are generally dependable, they can still experience faults like any other component. Thankfully, testing a relay is a relatively straightforward process– all you need is a multimeter. Read on to learn how to identify a faulty relay step-by-step.
Locate the relay: Find where the circuits enter and exit the relay. This region is typically marked by pins or terminals.
Check for voltage: With the multimeter set to measure voltage, probe the point where the relay plugs into the circuit. If it does not detect any voltage, inspect the associated fuse or switch for any defects that might interrupt the power supply.
Test ground connection: If voltage is present at the connection point, switch the multimeter to the continuity or resistance function and check for a good ground connection on the opposite side of the relay. A faulty ground can cause the relay to malfunction.
Verify power source: After successfully checking for voltage and testing the ground connection, check the voltage where the relay connects to the battery or another power source. If the multimeter detects no voltage here, it suggests a potential issue with a fuse or circuit breaker.
Test component connection: Use the multimeter’s continuity function to ensure a strong connection between the relay and the component it controls. If continuity exists and the previous steps did not reveal any other faults, it is likely a defective relay.
How Do You Identify a Faulty Relay?
Although relays are considered reliable mechanisms, they do have the capability of failing. Determining whether you have a faulty relay is simple and can be easily identified with the help of a multimeter.
Here are a few tips on how to use your multimeter to test a relay:
Remove the relay from the fuse box or vehicle.
Determine where the input and output points of the circuit are located on the relay.
Make sure your multimeter is set to ohm.
Connect the leads of the multimeter across the entrance and exit pins to determine resistance. Ideally, you’ll see a reading between 50 to 120 ohm.
If your multimeter has a reading of Open or Out of Range you may have a defective coil winding and the relay will need to be replaced.
If the reading looks good, you’ll want to connect the leads in between the switch pins. You should see a reading of OL or Open.
