Maxi relay vs. power relay

I have been using power relays for this particular recurring job, but wanting to know if a maxi would suffice.

In 12 volt automotive use, I have to supply one power bus with constant battery power, and another bus with “ignition on” power (coming on only when the vehicle’s ignition is on, and automatically back off when it’s off. This is where I have been using a 70 amp power relay, which is just about how much consumption I’m actually using on this bus. The several different pieces of hardware being powered are usually expensive but not fragile or delicate. It is common for this circuit to be kept on for 12 hours a day. Environmental conditions will vary and can be unpredictable at times. The normal life expectancy of this equipment is normally 5-7 years. This is a business setting, with work being done on customer’s vehicles. I can’t risk premature failure, component damage, or sub-par performance. I don’t want to try anything before I study it.

I’d prefer to be able to have a maxi (or two) do this job so that I can fit all of my power distribution components into a self contained PDU. The goal is to create a smaller footprint and keep components together in a safe space.

I was always told that this needed a power relay. I understand contacts are constructed differently between these two types. I understand how to read data sheets and that I need to stay within the limitations of the chosen relay. I know that vehicle manufacturers commonly use maxi relays, but I didn’t know if there was more to it that I’m not aware of.

Should I stick with the power relays, or would I be safe switching to the Maxi?

Is there any other information needed from me to clarify?

Hello @briansvs,

As I understand the technology, the term MAXI is an ISO form factor. An ISO maxi relay such as this TE product is designed to operate with 70 current. It has large and thicker blades when compared to the traditions plug in relay.

As for other information, the datasheet often lists design maximum ratings for ideal conditions. This is very important as the 70 A is specified at a temperature of 23 ˚C. This drops to 30 A at 125 ˚C.

Assuming your chosen relay has similar specifications, the device is woefully underrated for a 70 A continuous load.

While it works against your small PDU, it may be better to use something in this larger class:

Best wishes,

APDahlen

Some reference to the specific “power relay” in current use for sake of comparison would be helpful, seeing as how in Digi-speak the term references any relay rated for more than two amps.

As mentioned, current ratings commonly come with temperature qualifications, since keeping a lid on device temperatures is usually the reason why devices have current ratings at all.

If your existing relay has similar ratings with similar qualifications and no issues with reliability have been observed, there is a good likelihood that an automotive-style “maxi” relay would offer similar performance.

While I would agree with AP’s suggestion that it’s imprudent to design for continuous operation at a device’s rated maximums, it’s not clear from the question as posed whether it’s the actual continuous load that’s approaching this 70A figure or the theoretical maximum load that does so. There’s a very substantial difference between the two concepts. It’s also not clear from the question that the entire load needs to be serviced by a single relay. From a failure tolerance perspective there’s a case to be made for splitting it up, and five $5 relays are still 10x cheaper than one $250 relay. Also easier to find replacements if they’re ever needed…

Insofar as these “maxi” style relays are indeed used in/targeted to automotive applications, I would not hesitate to consider them for automotive applications. Just remember to vent them, as describe in this document.

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Thank you guys for the responses.

Here is what I’m referring to as the power relays that we have been using.
[PC775-1A-12C-X Picker Components | Relays | DigiKey]

The 70 amp load that I am referencing is the theoretical maximum, and I have not measured the actual continuous number.

I suppose it doesn’t need to be all on one relay, and I do like the idea of splitting up any future failures.

I guess what I’m getting at is that when I search “can I use a maxi relay instead of a power relay” or “maxi relay vs. power relay”, I never find a good solid answer. Let’s say the ratings on the data sheets were the same. Is there any reason why I should choose one over the other for my particular use, from the details that I’ve provided? The one thing I think I’m hearing is that the maxi relay performance may be a little more susceptible to temperature changes. Is that correct?

I need to hear it from a professional before I make a decision.

There’s a number of reasons for that:

  • “Power relay” is an ambiguous term
  • There are potentially a lot of variables involved, and a solid answer to such questions (unfortunately) means accounting for those details.
  • The internet is increasingly polluted with crummy information of specious origin.

Unfortunately I/we can’t offer you an answer of that sort. Per our terms and conditions it’s your responsibility to decide whether or not a given part is suitable for your needs. Most every component manufacturer/distributor is going to have a similar clause in the fine print.
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What I/we can do however, is offer guidance and reference to relevant information that would inform your decision. Grab a beverage, this might take a while…

For reference, I’ll be comparing the PC775-1A-12C-X relay you mentioned as your reference and the 1-1414286-0 mentioned by AP as an example of the “maxi” type relay.

As to the question of continuous current carrying capacity, the relevant portions of the respective datasheets are below. Both have to be de-rated with increasing temperature because Physics, but the “maxi” device actually seems to take a substantial lead at elevated temperatures.
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That is only one part of a complicated picture however, because most of the wear and tear on a relay’s contacts happens in millisecond-scale time spans as a relay opens and closes. This post explores those ideas in some depth, and has links to resources of a fairly serious nature.

The implication of this is that it’s tough to be really confident about how much stress a relay is experiencing without tools capable of measuring current on those time scales. We can talk about that if you like, but there’s a bit of a learning curve and convent tools for the task are probably going to be in four-figure price tag territory.

Along those lines however, the datasheets do provide some information about internal construction that’s relevant:
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What this is saying is that your “power” relay actually has two sets of contacts in parallel, one made of Tungsten (extremely high melting point) and silver alloy (conducts well) while the “maxi” relay in question just uses one set. The question then is “does it matter to you?” Useful information can be found in the service life/endurance ratings:


Both are rated for 100,000 operations, which equates to about 39 operations every single day for 7 years. Your “power” relay’s switched current specs are somewhat higher, particularly on the “make” side and if you’re switching capacitive loads like inverters that are particularly nasty on that end it might be the better choice. But there is a point when “enough” is indeed enough.

It’s a thing to consider. “What would happen when/if…” sorts of questions are a finer point of good design practice. I drove an ‘82 dodge in college that had one white wire in a harness underhood that rendered the thing completely ephing dead when disconnected. No lights, no engine, no power steering, no nuthin’.

I grant you one guess as to which wire decided to have an inside-the-insulation fracture while I was midway through a left turn on a 4-lane intersection in morning rush traffic…

Bottom line, both of the relays in question might adequately serve your needs, but a truly sound and grounded decision would require you to clarify what your needs actually are.

Side note: there are products like the 2297813-2 available from stock that might prove useful for your line of work.

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