National Instruments FP-RLY-422 User manual

FieldPoint ™is a trademark of National Instruments Corporation. Product and company names

mentioned herein are trademarks or trade names of their respective companies.

OPERATING INSTRUCTIONS

FP-RLY-422

4-Channel, SPDT Relay Module

These operating instructions describe the installation, features, and

characteristics of the FP-RLY-422. For details on configuring and

accessing the FP-RLY-422 over a network, refer to the user manual

for the particular FieldPoint network module you are using with

the FP-RLY-422.

Features

The FP-RLY-422 is a FieldPoint relay output module with the

following features:

• Four Single-Pole Double-Throw (SPDT) relay channels

• Switching capacity 3 A at 35 VDC or 250 VAC

• On/Off LED indicators

• Hot plug and play operation

• 3,000 V input to output isolation

• Double insulated for 250 V safe working voltage

• –40 to +70 °C operation

Installation

The FP-RLY-422 mounts on a FieldPoint terminal base

(FP-TB-xx) unit. The hot plug and play operation of the

FP-RLY-422 allows you to install it onto a powered terminal base

without disturbing the operation of other modules or terminal

bases. The FP-RLY-422 receives operating power from the

terminal base.

FP-RLY-422 2 www.natinst.com

To install the FP-RLY-422, refer to Figure 1 and follow these steps:

1. Slide the terminal base key to either position X (used for any

module) or position 7 (used for the FP-RLY-422 module).

2. Align the FP-RLY-422 alignment slots with the guide rails on

the terminal base.

3. Press firmly to seat the FP-RLY-422 on the terminal base. The

terminal base latch locks the FP-RLY-422 into place when it is

firmly seated.

Figure 1. Module Installation Diagram

Field Wiring

The terminal base has connections for each of the four relay

channels and an external supply to power field devices. Each relay

channel of the FP-RLY-422 has four terminals: one N.Open

(Normally Open), two I.Com (Isolated Common), and one

N.Closed(NormallyClosed). The external supply is not needed for

the internal operation of the FP-RLY-422; however, you may

connect an external supply to power field devices by connecting to

the V and C terminals of the terminal base. If you connect an

external supply to the V and C terminals, the total current supplied

cannot exceed 5 A.

Alignment

Slot

Key

Latch

Guide Rails

Terminal BaseI/O Module

Table 1 lists the terminal assignments for the signals of each

channel.

Figures 2a and 2b show examples of basic wiring connections.

Figure 2. Basic Field Connection

Table 1. Terminal Assignments

Channel

Terminal Numbers

N.Open I.Com N.Closed VSUP COM

0 1 2,3 417 18

19 20

1 5 6,7 821 22

23 24

2 9 10,11 12 25 26

27 28

313 14,15 16 29 30

31 32

a. Total Current Less

Than 5 Amps b. Total Current Greater

Than 5 Amps

VC Vsup

–

N.Open

I.Com

Vsup

N.Closed

COM

Load

N.Closed

I.Com

N.Open

I.Com

–

Load

FP-RLY-422 4 www.natinst.com

Relay Output Circuit

The outputs of the FP-RLY-422 consist of four independent

Form C electromechanical relays. The relays are

break-before-make, but only if you do not exceed the specified

relay operation speed. All relays remain in their power-up state or

OFF state (N.Closed connected to I.Com) until the relay (Channel)

is turned on. This will break the N.Closed–I.Com connection and

connect I.Com to N.Open. Choose the impedance of the loads so

that the current switched by any one channel is no more than 3 A.

Each relay can be controlled separately without affecting the

others, or all relays can change states at the same time.

There is an effective resistance of 100 mΩbetween I.Com and

N.Closed or N.Open. This resistance will cause a voltage drop. For

example, if the current is 3 A, the voltage drop across the I.Com

and N.Closed or N.Open terminals is 0.3 V.

Figure 3 shows the diagram of one channel’s relay output circuit.

Figure 3. Relay Output Circuit

N.Open

I.Com

COM

Vsup

I.Com

N.Closed

The maximum switching capacity of each relay is 3 A up to

250 VAC or 35 VDC. To switch greater DC voltages, refer to

Figure 4.

Figure 4. Maximum Current vs. DC Volts

Contact Protection for Inductive Loads

When inductive loads are connected to the relays, a large

counter-electromotive force may occur at relay switching time

because of the energy stored in the inductive load. These flyback

voltages can severely damage the relay contacts and greatly

shorten the life of the relay.

It is best to limit these flyback voltages at your inductive load by

installing, across your inductive load, a flyback diode for DC loads

or a metal oxide varistor (MOV) for AC loads. Refer to the next

section, Guidelines for Selecting Contact Protection Circuits, for

more information.

In addition, the FP-RLY-422 contains its own internal protection

MOV to prevent excessively high voltage from being applied

across the contacts. Each channel contains two MOVs: one

betweenN.Closed and I.Com andonebetweenN.OpenandI.Com.

However, National Instruments still recommends the use of a

protection circuit across your inductive load.

2004060

DC Volts

Current

(Amps)

80 100 120

1.5

2.5

Safe Operating

Region

FP-RLY-422 6 www.natinst.com

Guidelines for Selecting Contact

Protection Circuits1

Proper selection is critical as the useof a contact-protection device

can extend contact life. When mounting the protection device,

always locate it near the immediate area of the load or contact.

Typically you should mount a protective device within 18 in. of the

load or contact.

Typically, contact-protection circuits are provided foran overview,

but you should thoroughly examine the circuit you are planning

to use.

Diode and Zener Diode Circuit

Diode Circuit

1 This section has been reprinted with permission from American Zettler, Inc.

Diagram Notes

Use in DC applications only.

Use when diode circuit causes too long

release time.

Use zener diode with zener voltage about

equal to power supply voltage.

Diagram Notes

Use in DC applications only.

Compared to RC type, circuit delays release

time (2 to 5 times values stated in catalog).

For larger voltages, use diode with reverse

breakdown 10 times circuit voltage and

forward load circuit.

For smaller voltages, use reverse breakdown

voltage of 2 to 3 times power supply voltage.

Load

CR Circuits

Varistor Circuit

In-Rush Current

The type of load and its in-rush current characteristics, together

with switching frequency, can cause contact welding. For loads

with in-rush current, measure the steady state current and in-rush

current to determine the proper relay. Some typical types of loads

and the in-rush current they create are summarized in the following

table.

Diagram Notes

Circuit A is suitable for AC or DC

applications, but if used with AC

voltage, impedance of the load

should be smaller than the CR

circuit’s. Do not utilize for timer

loads, as leakage current can cause

faulty operations.

Circuit B is suitable for AC or DC.

If the load is a relay or solenoid,

release times lengthen. Effective

when connected to both contacts,

power supply voltage across the

load is 100 to 200 V.

Diagram Notes

Effective for AC and DC

applications.

Circuitslightlydelaysreleasetime.

Effective when connected to both

contacts, power supply voltage

across the load is 100 to 200 V.

Load

FP-RLY-422 8 www.natinst.com

Status Indicators

Figure 5 shows the module label and status indicators. You can

remove the insertable label to see wiring diagrams for the relay

channels.

Figure 5. Status Indicators and Module Label

After the module has been inserted into a terminal base (and

power is applied), the green POWER indicator lights and the

FP-RLY-422 informs the network module of its presence. When

the network module recognizes the FP-RLY-422, the network

module sends initial configuration information to the FP-RLY-422.

After receiving this initial information, the green READY

indicator lights and the FP-RLY-422 is in its normal operating

mode. In addition to the green POWER and READY indicators,

each channel has two, green, output state indicators labeled

Table 2. Typical Load Types and In-Rush Currents

Type of Load In-Rush Current

Resistive load Steady-state current

Solenoid load 10 to 20 times the steady-state current

Motor load 5 to 10 times the steady-state current

Incandescent lamp load 10 to 15 times the steady-state current

Mercury lamp load Approximately 3 times the steady-state

current

Sodium vapor lamp load 1 to 3 times the steady-state current

Capacitive load 20 to 40 times the steady-state current

Transformer load 5 to 15 times the steady-state current

4-Ch. SPDT Relay

0123

NO NC NO NC NO NC NO NC

NO and NC. The indicators show which terminal is connected

to I.Com.

Isolation and Safety Guidelines

Caution Read the following information before

attempting to connect ANY circuits that may contain

hazardous voltages to the FP-RLY-422.

This section describes the isolation of the FP-RLY-422 and its

compliance with international safety standards. The outputs are

isolated from the backplane of the terminal base with an isolation

barrier designed and tested to protect against fault voltages of upto

3000 Vrms. In addition, the FP-RLY-422 provides double

insulation (compliant to UL and IEC safety standards) for

working common-mode voltages of 250 Vrms. Safety standards

(such as those published by UL and IEC) require the use of double

insulation between hazardous voltages and any human-accessible

parts or circuits. You should never attempt to use any isolation

product between human-accessible parts (such as DIN rails or

monitoring stations) and circuits that may be at hazardous

potentials under normal conditions, unless the product is

specifically designed (as the FP-RLY-422 is) for such an

application.

Even when a product like the FP-RLY-422 is used in applications

with hazardous potentials, follow these guidelines to ensure a safe

total system:

• The safety isolation of the FP-RLY-422 is from input to output,

not between channels on the same module. If any of the

channels on a module are wired at a hazardous potential,

ensure that all other devices or circuits connected to that

module are properly insulated from human contact.

•Donot share the external supply voltages (V and C on the

terminal base) with other devices (including other FieldPoint

devices) unless those devices are also isolated from human

contact.

FP-RLY-422 10 www.natinst.com

• As with any hazardous voltage wiring, ensure that all wiring

and connections meet with applicable electrical codes or

common sense practices. Mount terminal bases in an area,

position, or cabinet that prevents accidental or unauthorized

access to wiring with hazardous voltages.

• The isolation of the FP-RLY-422 is certified as double

insulated for normal operating voltages of 250 Vrms. Do not

use the FP-RLY-422 as the sole isolating barrier between

human contact and working voltages of more than 250 Vrms.

Specifications

The following specifications are typical for the range

–40 to +70 °C, unless otherwise noted.

Input Characteristics

Number of channels..........................4

Relay type.........................................1 Form C (SPDT)

Nonlatching

Maximum Switching Capacity (Resistive Load)

AC ..............................................3 A at 250 VAC

DC ..............................................3 A at 35 VDC

2 A at 40 VDC

1 A at 55 VDC

0.4 A at 120 VDC

Minimum switching voltage.............10 mA at 5 VDC

On resistance.....................................100 mΩ

Off state leakage ...............................0.3 µA at 250 VAC

Expected Life

Mechanical .................................10 ×106operations min.

Electrical (at 30 cpm).................300,000 operations at 3 A,

35 VDC

100,000 operations at 3 A,

250 VAC

Maximum Switching Frequency

Mechanical .................................20 operations per second

Electrical.....................................1 operation per second at

maximum load

Relays operate time...........................10 ms typical, 13 ms max.

Relays release time ...........................5 ms typical, 7 ms max.

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