A relay is simply an electrical switch but instead of being operated by someone to turn it on

or off, it is operated by another electrical circuit. So, essentially a relay is an electrically

operated switch. We typically see a relay is used when we need to control a switch that has
high voltage or high current passing through it and it is much safer to operate it by another
switch instead of operating it directly. By using relays, you can significantly increase the
operational safety of the circuit.

Using relays also allows you to control several devices by a single switch instead of using
several different large switches. Relays can also be combined with timers and logic circuits
which, makes them more suitable for automation.

You may find relays in electrical devices that operate several other electrical devices such as
motors, fans, blowers, etc. In industrial applications, they are commonly used in control
panels for various tasks such as controlling a motor or valve or other electrical devices in the
system.

How do relays work?

A relay consists of two different circuits that work in tandem to turn a switch on or off. The
first circuit drives an electromagnet and creates a magnetic field. The second circuit contains
a set of contacts and a separate power source. The magnetic field pulls the contact from the
other circuit and closes it which allows the current to pass through the contacts, which allows
the load to become energized. When the coil is de-energized, the magnetic field is lost which
lets the contact be pushed back into its original open state, which de-energizes the circuit.

Purpose of Relays
Protective relays monitor critical operational parameters and initiate an emergency shutdown
when they detect out-of-limit conditions. Protective relays detect abnormal conditions and
shut down the equipment to save the equipment and related systems. However, if the relays
operate incorrectly then it will lead to the shut down of the equipment without any reason.

Electrical protective relays are calibrated with settings that are determined during the system
design phase. Initial settings are provided when relays are initially installed. However,
electrical systems change as a new generation of equipment is added or it replaces the
obsolete equipment. This may mean that those relay settings become no longer correct and
these incorrect relay settings can be hazardous to the personnel and the equipment.

How to Test a Relay

There is a large number of relay types, and it is quite possible to find a mix of several relay
types and functions in the same system that needs to be tested with the relay test
set. Therefore the way to test a relay will depend on many different considerations based on
the type and function of the relay.

Relay Test Set

Modern relay test sets are capable of testing all types of single-phase equipment, over-
current, under & overvoltage, leakage current, power, differential, and directional relays, etc.
These test sets have a current transformer, auto variable transformers, contactors, time
interval meter, etc. all housed in one box. Suitable switches are provided for the selection of
current, voltage ranges, and selection of relay type.

Why is calibration important?

As electronic components age, they drift from their original specifications. A measuring
device will lose its ability to measure accurately. Therefore, it should be calibrated to ensure
that it works correctly within the expected ranges.
Calibration is extremely important because it ensures that your measurements are accurate as
they are the basis for the quality and safety of the products to be tested. Calibration saves
money by detecting potential manufacturing errors before they occur. Issues can be
proactively resolved and corrected during the normal maintenance period instead of repairs in
forced shutdowns.

If you are performing a measurement where the results will make a critical decision such as a
safety test, you should get your equipment calibrated. This is especially important if you want
your results to correlate with international standards.

The Benefits of Calibration

• Assure precise measurements.
• Increased safety and improved compliance with regulations.
• Increased profitability by either increasing revenues or cutting costs.
• Improving product quality and services with improved customer acceptance.
• Reducing production errors and recalls.
• Avoiding false acceptance and rejection of product.

The cost of not calibrating means higher production cost, false acceptance and false rejection
of products, and increased plant shutdowns. Personal injury and unnecessary legal costs are
some of the big risks of not calibrating.