I/O Relay Modules

Part Number	Description / PDF	Quantity
IAC-15 TE Connectivity Potter & Brumfield Relays	AC INPUT MODULE 120V	0
EXI25CH Weidmuller	DELCON 24VAC INPUT PLUG IN RLY	0
EXO48CHA Weidmuller	DELCON PL RL 48VDC 250VDC 1.8A	0
EXI120CHI Weidmuller	DELCON 120VAC INPUT PLUG IN RL	0
SLO24CRX Weidmuller	DC OUTPUT MODULE 10A	0
SLI250CH Weidmuller	DC INPUT MODULE 250V	0
SLI250CR Weidmuller	DC INPUT MODULE 250V	6
EXO12CHA Weidmuller	DELCON 12VDCIN/0-250VDC 1.8A	0
70G-IAC15A Grayhill, Inc.	AC INPUT MODULE 240V	0
70M-IDC5G Grayhill, Inc.	AC/DC INPUT MODULE 35-60V	0
EXO12TH Weidmuller	DELCON 12VDCIN/0-240VAC 3A OUT	0
EXO48CHXSN Weidmuller	DELCON DN RL 48VDC 24VDC 10A	0
39.21.0.024.0060 Finder Relays, Inc.	EMR MASTER OUTPUT SPDT	0
SLO24CRSN Weidmuller	DC OUTPUT MODULE 3A	0
EXO5CHX Weidmuller	DELCON PLUG IN RELAY 10A	0
SLI120CRSN Weidmuller	AC INPUT MODULE 120V	0
SLI24CR Weidmuller	DC INPUT MODULE 24V	0
IAC-5A TE Connectivity Potter & Brumfield Relays	AC INPUT MODULE 240V	30
IACM-15 TE Connectivity Potter & Brumfield Relays	IACM-15=IO MODULES	0
SLI120CR Weidmuller	AC INPUT MODULE 120V	22

I/O Relay Modules

1. Overview

I/O Relay Modules (Input/Output Relay Modules) are electronic devices that enable signal conversion and electrical isolation between control systems and external equipment. They act as intermediaries to control high-power circuits using low-power signals, playing a critical role in automation systems, industrial machinery, and smart infrastructure. These modules ensure safe and reliable switching operations in applications ranging from factory automation to renewable energy systems.

2. Main Types and Functional Classification

Type	Functional Characteristics	Application Examples
Electromagnetic Relays	Mechanical switching via electromagnetic coils, high current capacity	Industrial motor control, HVAC systems
Solid-State Relays (SSR)	No moving parts, fast switching, low EMI	Temperature control systems, semiconductor equipment
Hybrid Relays	Combines electromagnetic and solid-state advantages	Precision manufacturing, aerospace systems
Programmable Relays	User-configurable logic functions	Custom automation systems, R&D equipment
Smart Relays	Integrated sensors, IoT connectivity, self-diagnosis	Smart grids, predictive maintenance systems

3. Structure and Components

A typical I/O Relay Module consists of:

Housing: Flame-retardant polymer casing (UL 94 V-0 rated)
Contact System: Silver alloy for low resistance (AgSnO typical)
Coil Assembly: Copper winding with thermal class F insulation
Drive Circuitry: Transistor-based drivers for DC types or zero-crossing detection for AC
Isolation Layer: Reinforced insulation barrier (2500 Vrms basic insulation)

4. Key Technical Specifications

Parameter	Significance	Typical Range
Rated Voltage	Determines application circuit compatibility	5VDC-250VAC
Current Rating	Affects power handling capability	1A-100A
Switching Speed	Critical for real-time control systems	0.5ms-20ms
Electrical Life	Directly impacts maintenance intervals	10 - 10 operations
Insulation Resistance	Ensures safety isolation	>100M @ 500VDC

5. Application Areas

Industrial Automation: PLC systems, assembly line robots
Energy Systems: Smart grid controllers, solar inverters
Transportation: Railway signaling, EV charging stations
Medical Equipment: Diagnostic imaging systems, infusion pumps

6. Leading Manufacturers and Products

Manufacturer	Representative Product	Key Features
Omron	MY2N-J	30A rating, LED status indicator
Siemens	SIMATIC ET 200	PROFINET interface, hot-swappable
Schneider Electric	Zelio SR2	Programmable, LCD display
ABB	AF250-30L	Energy-efficient coil, 125kHz switching
Phoenix Contact	PSR-SCP-24DC-CT	Safe separation, configurable delay

7. Selection Recommendations

Key considerations include:

Match voltage/current ratings with load requirements (125% safety margin recommended)
Environmental factors: operating temperature (-40 C to +85 C typical)
Mounting type: PCB, DIN rail, or panel mount
Communication protocol compatibility (Modbus, EtherCAT, etc.)
Failure Mode Analysis: Choose failsafe configuration per application needs

8. Industry Trends

Emerging developments include:

Integration with IIoT protocols (OPC UA, MQTT)
Miniaturization: 30% size reduction in 2023 models
Energy efficiency improvements: >85% coil power reduction
AI-enabled predictive maintenance features
Increased adoption of wide bandgap semiconductors in SSRs

Application Case Study

A automotive manufacturing plant implemented Omron MY4NJ relays in robotic welding systems, achieving:

40% reduction in switching-related downtime
25% energy savings through optimized coil drive
Integration with existing PROFINET network