Connecting Indications on Indication-less Relays

One of the possibilities is that rather than modify the existing relays, the vendor wants to sell new ones that do have status indications.

There is an economic balance somewhere between replacing them and modifying them with the inherent risks to process and personnel in the event of failure(s) of the modified one(s). The balance cannot be seen from here.

Once you modify anything about the relay any certifications (UL, CE, etc.) are automatically no longer valid and your company bears the responsibility for any subsequent problems. The vendor is just protecting his good name, and rightfully so.

As #2↑: so just because one could do something doesn't mean one should do something.

I bet your not using all the contacts on all of the indication-less relays. Put your indication circuit on the N.O. contact of any that have a spare, and replace the ones that don't with the indication type.

Hi Kilowatt0

Thats good idea. I will do at least on those relays which have spare contact.

I think you are much better off investing your time in finding a replacement relay. I fail to understand that it is not possible, unless you are a criminal or terrorist and cannot buy components without being exposed to authorities. Aside from the other perfectly valid reasons why Omron would not be interested in helping, from YOUR standpoint the time it takes for you to remove and disassemble a relay, design, find, procure and solder on the components, then reassemble, reinstall and test the relay will likely make it cost you 4-5X the price of an indicator style. Relays are relays, they all have the same pinouts in that style. There are very inexpensive versions from people like Schrack which have a mechanical red flag that provides the same sort of indication, just not as bright.

Your problem is very common because some purchaser thought they would save a small amount of money on every relay. They have no concept of how much it slows down troubleshooting.

It is not necessary to open up each relay case to install your indicators. You can just solder a current limiting resistor to one of the leads of your indicator and connect the remaining leads to the terminals that your relay plugs into for coil voltage.

While it would be nice to throw away the non-indicated relays, I'm sure some wingnut in accounting would have a heart attack. You can use a piece of heat shrink tubing over the resistor and lead to your indicator. The neon types will work in any polarity but you will have to watch the polarity of your LED indicators. Or, you could buy bipolar LED's but we wouldn't want to make it too easy....

Buy a bunch of these and tape one to every non-indicating relay in your shop.

Non Contact Voltage Tester - Image Results

Why is it impossible to replace the relays? If it is cost factor. Your more then going to expend that in labor and parts to do it like that. More so in lost production time as you make the modifications.

Anyway the addition of parts in the relay case may hinder contact movement causing them to fail. If you must install the lamp place it on socket screw terminals.

That little light also can cause problem in troubleshooting. Too many take it for granted that the light works so does the relay. Just another idiot light.

"That little light also can cause problem in troubleshooting. Too many take it for granted that the light works so does the relay. Just another idiot light."

I think that is another excellent point.

What quantities are you talking about here? Why can't you change them out as they fail?

I can buy Omron 24VDc relays with indicator LEDS here for approx USD2 each. That is retail price not wholesale...

Agree with ozzb re the dangers of relying on lamps to determine proper function. If the coil was burnt the lamp would still shine when energised.