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Diode Parallel to a DC Contactor

01/18/2020 1:02 AM

I haven't seen one yet until the other week. I was surprised what a rectifier was doing parallel the actuation terminal of a dc contactor. A reverse baised diode could do no harm but what if connected as a forward biased. I could not imagine that it could potentially effect sort of lessen the current of a contactor.

What do you think?

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#1

Re: Diode parallel to a DC contactor

01/18/2020 2:33 AM

..."When the power supply is connected to the relay, the inductance coil’s voltage builds up to match that of the power source. The speed at which current can change in an inductor is limited by its time constant. In this case, the time it takes to minimize current flow through the coil is longer than the time it takes for the power supply to be removed. Upon disconnection, the inductance coil reverses its polarity in an attempt to keep current flowing according to its dissipation curve (i.e., % of maximum current flow with respect to time). This causes a huge voltage potential to build up on the open junctions of the component that controls the relay.

This voltage built up is called flyback voltage. It can result in an electrical arc and damage the components controlling the relay. It can also introduce electrical noise that can couple into adjacent signals or power connections and cause microcontrollers to crash or reset. If you have an electronics control panel that resets each time a relay is de-energized, it’s highly possible you have an issue with flyback voltage.

To mitigate this issue, a diode is connected with reverse polarity to the power supply. Placing a diode across a relay coil passes the back EMF and its current through the diode when the relay is energized as the back EMF drives the flyback protection diode in forward bias. When the power supply is removed, the voltage polarity on the coil is inverted, and a current loop forms between the relay coil and protection diode; the diode again becomes forward biased. The diode allows current to pass with minimal resistance and prevents flyback voltage from building up, hence the name flyback diode."...

https://resources.altium.com/bill-of-materials-blog/why-you-should-use-a-flyback-diode-in-a-relay-to-prevent-electrical-noise-in-your-circuits

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#15
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Re: Diode parallel to a DC contactor

01/20/2020 9:41 AM

An excellent description. GA from me

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#2

Re: Diode Parallel to a DC Contactor

01/18/2020 4:01 PM

As SE explained, it's a "flyback diode" used to mitigate contactor pitting.

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#4
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Re: Diode Parallel to a DC Contactor

01/18/2020 6:22 PM

Can I use a resistor instead?

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#6
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Re: Diode Parallel to a DC Contactor

01/18/2020 6:55 PM

A resistor will draw current because it's in parallel with the coil...BOTH diode and resistor is better.

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#10
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Re: Diode Parallel to a DC Contactor

01/19/2020 12:04 PM

The flyback resistor is a common technique especially with large contactors. It significantly reduces voltage transients and takes stress off the driving circuit.

When the drop out time of the contactor becomes critical we usually add a resistor in series with the diode. A good starting point is one equal to the coil resistance - that way the inductive kick is only equivalent to the rated voltage. The drop out time is cut in half.

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#11
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Re: Diode Parallel to a DC Contactor

01/19/2020 3:17 PM

A resistor is problematic, to have one with a low enough impedance and high enough wattage to deal with the flyback, would put an unnecessary load on the circuit.

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#13
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Re: Diode Parallel to a DC Contactor

01/20/2020 1:29 AM

No. The diode stops any power dissipation except for the flyback energy. E=1/2 i^2 L

Even with 1 Henry and 1 amp you only have 1 watt sec to dissipate, and half that will be in the coil resistance anyways.

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#3

Re: Diode Parallel to a DC Contactor

01/18/2020 5:16 PM

Here is a mechanical analogy:

Current through an inductor (coil) is like a moving mass. To stop a moving mass suddenly (shutting off the current) results in a large force (voltage). The diode is a path for the current to circulate, to decay slowly and not generate a high voltage pulse.

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#5
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Re: Diode Parallel to a DC Contactor

01/18/2020 6:24 PM

But, which is more suitable, a diode or an MOV?

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#7
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Re: Diode Parallel to a DC Contactor

01/18/2020 7:58 PM
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#8
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Re: Diode Parallel to a DC Contactor

01/19/2020 1:25 AM

gutmonarch, the idea is to only get rid of the reverse voltage, and for that we use a component that only conduct in one direction but is off in the other direction, that is a diode. Resistors and MOV's can conduct in both directions. The diode is there for short out the reverse voltage created by the collapse of the magnetic field over the coil of the relay. The diodes only and exclusive job is to protect the other components in the circuit from the back EMF of the coil of that Relay it is over.

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#12
In reply to #5

Re: Diode Parallel to a DC Contactor

01/19/2020 3:18 PM

MOV's are good for AC, this is DC, Diode will do nicely.

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#16
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Re: Diode Parallel to a DC Contactor

01/20/2020 12:36 PM

Sometimes a TVS (or Zener diode) is used in series with the diode to more quickly dissipate the stored energy in the relay coil to allow the relay contacts close sooner when the coil voltage is removed. I've not yet seen an MOV used to quench the coil current.

(choice of PN diode and Zener diode will vary depending on the application)

In other words, use the parts below at your own risk.

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#9

Re: Diode Parallel to a DC Contactor

01/19/2020 5:40 AM

The purpose of the diode is to act as a shunt when the coil is disconnected from the supply. Normally the diode is reverse biased as shown in the connection but when the coil is opened the collapsing magnetic field generates a reverse polarity voltage which the diode shunts. Depending on the type of diode used it will conduct between 0.2V for a Shottke and 0.6V for a silicon diode.

If the diode is not used then the reverse voltage spike is impressed across the switching element which can be solid state, relay contacts, switch mechanism anything to control power to the coil.

If the DI/DT change in current over change in time is very high sometimes a resistor is used in series with the diode however the coil may hold in for slightly longer due to the time constant of the inductance, capacitance of the coil and the resistor value.

Resistors can be used but they consume power and generate heat because they shunt the coil supply under normal operating conditions.

MOVs require a certain voltage to begin conducting and if you choose to use one of them then the conduction point needs to be high enough not to conduct under normal supply conditions but low enough to shunt too high a reverse voltage before damage can occur to other equipment.

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Re: Diode Parallel to a DC Contactor

01/20/2020 5:13 AM
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#17

Re: Diode Parallel to a DC Contactor

01/22/2020 7:46 AM

the facts have been discussed is really important. Thank you so much for sharing a great post.

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