G2RL-2 DC12

Product Overview of the Omron G2RL Series

The Omron G2RL series represents a family of general-purpose PCB-mounted power relays engineered for applications requiring reliable electromagnetic switching in compact form factors. These relays are designed with a maximum height of 15.7 mm, making them suitable for integration into miniaturized equipment where space constraints are a primary design consideration. The series encompasses multiple contact configurations and coil voltage ratings, providing flexibility for diverse circuit requirements across industrial machinery, home appliances, and office automation equipment.

The G2RL series builds upon proven relay technology while introducing refinements in power efficiency and operational reliability. Each relay variant within the series maintains consistent mechanical interfaces and electrical principles, allowing designers to select specific models based on load requirements and environmental conditions without requiring fundamental circuit redesigns.

Structural Design and Form Factor of the G2RL Series

The G2RL series employs a low-profile design philosophy that distinguishes it from earlier relay generations. With a maximum height of 15.7 mm and a footprint of 29 mm by 12.7 mm, these relays occupy minimal PCB real estate while maintaining robust construction. The relay body features flux-protective sealing with two designated sealing holes on the case, allowing controlled venting while preventing contamination from flux residues during manufacturing processes.

The through-hole mounting configuration utilizes PCB mounting holes with 1.3 mm diameter specifications. Different model variants within the G2RL series feature varying numbers of mounting holes—ranging from four to eight holes depending on the contact configuration—to accommodate different electrical topologies. This modular approach to mounting allows manufacturers to standardize PCB layouts across multiple relay types while maintaining mechanical stability.

The terminal arrangement follows a standardized pattern across the series, with coil terminals positioned at specific locations and contact terminals arranged according to the relay's contact form. The relay exhibits no coil polarity requirement, simplifying installation procedures and reducing the potential for assembly errors. Terminal spacing of 4.6 mm between adjacent pins facilitates standard PCB trace routing and component placement algorithms used in automated manufacturing environments.

Contact Configuration Options in the G2RL Series

The G2RL series offers multiple contact configurations to address different switching requirements. The primary contact forms available include SPST-NO (single-pole single-throw normally open), SPDT (single-pole double-throw), DPST-NO (double-pole single-throw normally open), and DPDT (double-pole double-throw) arrangements. This variety enables designers to select relays that match their specific circuit topologies without requiring additional switching components.

Within each contact configuration, the series provides three distinct performance tiers: standard type, high-capacity type, and high-sensitivity type. The standard type relays handle 8 A at 250 VAC or 8 A at 30 VDC, representing the baseline switching capacity suitable for general-purpose applications. The high-capacity variants increase switching capacity to 16 A at 250 VAC or 16 A at 24 VDC, accommodating applications with elevated power requirements. The high-sensitivity type operates at reduced power consumption levels, requiring only 250 mW of coil power, making these variants suitable for battery-powered or energy-constrained systems.

All contact variants utilize silver-alloy material with cadmium-free composition, meeting environmental regulations while maintaining reliable electrical contact characteristics. Contact resistance remains below 100 mΩ under specified measurement conditions, ensuring minimal voltage drop across the relay contacts during operation.

Coil Specifications and Operating Characteristics of the G2RL Series

The G2RL series offers coil voltage ratings of 5 VDC, 12 VDC, 24 VDC, and 48 VDC, with specific voltage options varying by model variant. The coil resistance values differ significantly across voltage ratings, reflecting the design optimization for each voltage level. At 5 VDC, the standard coil resistance measures 80 ohms with a rated current of 62.5 mA. At 12 VDC, the coil resistance increases to 360 ohms with a rated current of 33.3 mA. At 24 VDC, the resistance reaches 1,440 ohms with a rated current of 16.7 mA. At 48 VDC, the resistance measures 5,358 ohms with a rated current of 8.96 mA.

The must-operate voltage specification indicates the minimum voltage required to reliably energize the relay coil. For standard models, this threshold is set at 10% of the rated voltage, ensuring reliable operation even under modest supply voltage variations. The must-release voltage, typically specified at 70% of rated voltage for standard models, defines the voltage level below which the relay contacts return to their de-energized state. These specifications establish the operating window within which the relay functions predictably.

Operate time—the interval between coil energization and contact closure—measures 15 milliseconds maximum across the G2RL series. Release time, the interval between coil de-energization and contact opening, measures 5 milliseconds maximum. These timing characteristics enable designers to predict relay response in time-sensitive applications and coordinate relay operation with other circuit elements.

Electrical Performance and Switching Capacity of the G2RL Series

The maximum switching voltage rating for the G2RL series reaches 440 VAC or 300 VDC, establishing the upper voltage limit for relay contact switching operations. The maximum switching current varies by model type: standard models handle 12 A, high-capacity models accommodate 16 A, and high-sensitivity models switch 10 A maximum. These ratings define the envelope of electrical loads the relay can safely interrupt without contact degradation or arcing phenomena.

The dielectric strength between coil and contacts withstands 5,000 VAC at 50/60 Hz for one minute, providing robust isolation between the control circuit and the switched load. Between contacts of the same polarity, the dielectric strength measures 1,000 VAC under identical test conditions. Between contacts of different polarity, the dielectric strength reaches 2,500 VAC, accommodating applications where contacts must withstand significant voltage differentials.

Impulse withstand voltage testing at 10 kV (1.2 × 50 microsecond waveform) demonstrates the relay's ability to survive transient overvoltage events common in industrial environments. Insulation resistance between coil and contacts exceeds 1,000 megohms, indicating excellent isolation characteristics that prevent leakage current paths between circuits.

The electrical endurance characteristics of the G2RL series vary significantly based on load type and operating conditions. Standard models demonstrate 30,000 operations at 250 VAC with 8 A resistive load at 85°C. High-capacity models achieve 50,000 operations under identical conditions. High-sensitivity models complete 50,000 operations at 250 VAC with 10 A resistive load. These endurance ratings reflect the cumulative effect of contact erosion, material migration, and mechanical wear during extended operation.

Thermal Management and Temperature Operating Range of the G2RL Series

The G2RL series maintains operational capability across an ambient temperature range of -40°C to 85°C for standard models, with specialized variants extending the upper limit to 105°C. This extended temperature range accommodates applications in harsh industrial environments where ambient temperatures exceed typical office or consumer equipment conditions. The relay operates without icing or condensation formation within these temperature boundaries.

Ambient operating humidity specifications range from 5% to 85% without icing or condensation, establishing the moisture environment in which the relay maintains specified performance. The relay's flux-protective design with sealing holes provides resistance to moisture ingress while allowing controlled venting of internal pressure differentials.

Temperature effects on relay performance manifest through changes in coil resistance and operating voltage thresholds. As ambient temperature increases, coil resistance increases slightly due to the positive temperature coefficient of copper wire. Simultaneously, the must-operate and must-release voltage thresholds shift, requiring designers to account for temperature-dependent variations when establishing supply voltage margins. The G2RL-1A-E-CV variant, specifically designed for 105°C operation, incorporates design modifications that maintain stable operating characteristics across this extended temperature range.

Mechanical Durability and Environmental Resilience of the G2RL Series

The G2RL series demonstrates mechanical durability through 20,000,000 operations at 18,000 operations per hour for standard models, representing approximately 1,111 hours of continuous operation at maximum switching frequency. This durability specification reflects the mechanical robustness of the relay's contact arm, spring mechanisms, and electromagnetic structure.

Vibration resistance testing establishes the relay's ability to function reliably in environments subject to mechanical oscillation. Destruction-level vibration testing applies 10 to 55 to 10 Hz frequency sweeps with 0.75 mm single amplitude (1.5 mm double amplitude) without causing permanent relay damage. Malfunction-level vibration testing applies identical frequency and amplitude parameters to verify that the relay does not experience spurious contact opening or closing during vibration exposure.

Shock resistance testing evaluates relay performance when subjected to sudden acceleration events. Destruction-level shock testing applies 1,000 m/s² acceleration in three orthogonal directions without causing permanent damage. Malfunction-level shock testing applies 100 m/s² acceleration both with and without relay energization to verify that shock events do not cause unintended contact transitions.

The G2RL series incorporates flux-protective design as standard, featuring a sealed case with controlled venting that prevents flux residues from contaminating internal relay components. This design approach eliminates the need for post-manufacturing cleaning procedures that would otherwise require boiling or soaking in water—processes that could damage relay components or introduce moisture into sealed cavities.

Power Consumption Optimization in the G2RL Series

Standard G2RL models consume approximately 400 mW at rated coil voltage for 5 VDC variants, approximately 400 mW for 12 VDC variants, approximately 120 mW for 24 VDC variants, and approximately 430 mW for 48 VDC variants. These power consumption levels reflect the electrical resistance of the coil winding and the applied voltage according to the relationship P = V²/R.

The G2RL series incorporates pulse-width modulation (PWM) control capability in designated -PW1 model variants, enabling significant power consumption reduction during the relay holding phase. After the relay contacts close in response to coil energization, the applied voltage can be reduced to a holding voltage of 55% of the rated voltage while maintaining contact closure. This voltage reduction decreases power consumption to approximately 120 mW across all voltage ratings, representing a 70% reduction compared to continuous full-voltage operation.

The PWM control strategy requires that the rated voltage be applied for a minimum of 100 milliseconds during the initial energization phase to ensure reliable contact closure. Following this initial energization period, the voltage can be reduced to the holding level. A voltage of at least 55% of rated voltage must be maintained to prevent unintended contact opening due to voltage fluctuations. This approach proves particularly valuable in battery-powered applications or systems where thermal management of relay coils presents design challenges.

Standards Compliance and Safety Certifications for the G2RL Series

The G2RL series carries multiple international safety certifications demonstrating compliance with recognized standards. UL recognition (File No. 41643) and CSA certification (File No. LR31928) establish compliance with North American electrical safety standards. EN/IEC and VDE certification (Certificate No. 119650) demonstrates compliance with European electrical safety requirements. CQC certification (Certificate No. CQC17002171904) establishes compliance with Chinese electrical safety standards.

Specific model variants within the G2RL series meet additional specialized standards. The -HA variants comply with IEC/EN 60335-1, the standard for household and similar electrical appliances, enabling use in consumer equipment applications. The -CV variants satisfy ambient operating temperature requirements of 105°C, extending applicability to high-temperature industrial environments.

Certain G2RL variants meet IEC/EN 60079-1 and IEC/EN 60079-15 standards for equipment used in explosive atmospheres. These standards establish requirements for enclosed-break devices (Group IIA) and sealed devices, enabling relay use in environments where flammable gases or vapors may be present. Group IIA classification encompasses hydrogen-air mixtures at 55% ± 0.5% concentration, covering applications in chemical processing, petroleum refining, and similar industrial sectors.

The relay design incorporates reinforced insulation between the coil and contact circuits, achieving a rated insulation voltage of 250V. Creepage and clearance distances of 8 mm minimum between conductive elements meet pollution degree 3 requirements, appropriate for industrial environments where conductive contamination may accumulate on insulation surfaces. The relay base material achieves a Tracking Index (PTI) of 250V minimum, indicating resistance to electrical tracking and surface degradation under high-voltage stress.

Application Scenarios and Selection Guidance for the G2RL Series

The G2RL series finds application across diverse equipment categories where reliable electromagnetic switching in compact form factors provides design advantages. Home appliance applications include refrigerator compressor control, washing machine motor switching, and microwave oven power management. The flux-protective design eliminates post-manufacturing cleaning requirements, reducing production costs in high-volume consumer equipment manufacturing.

Office automation equipment applications include printer motor control, copier paper feed mechanisms, and document scanner drive circuits. The compact 15.7 mm height enables integration into equipment with space constraints while maintaining the electrical performance required for reliable operation.

Industrial machinery applications encompass motor starter circuits, solenoid valve control, and process automation switching. The extended temperature range variants accommodate equipment operating in uncontrolled environments where ambient temperatures may exceed typical office conditions. The high-capacity variants handle the elevated switching currents required in industrial power distribution circuits.

Selection of appropriate G2RL variants requires consideration of multiple parameters. The contact configuration must match the circuit topology—SPDT variants for applications requiring simultaneous switching of two independent circuits, DPDT variants for applications requiring coordinated switching of multiple loads. The coil voltage must align with available control circuit supply voltages, with 12 VDC and 24 VDC representing the most common industrial control voltages.

The contact rating must accommodate the maximum load current and voltage without exceeding the relay's switching capacity. Applications with elevated switching currents benefit from high-capacity variants, while battery-powered or thermally constrained applications benefit from high-sensitivity variants. The operating temperature range must encompass the equipment's anticipated ambient conditions, with -HA variants selected for consumer applications and -CV variants selected for high-temperature industrial environments.

The PWM-capable -PW1 variants provide significant advantages in applications where continuous relay energization would generate excessive heat or drain battery capacity. These variants prove particularly valuable in automotive applications, portable equipment, and industrial control systems where power efficiency directly impacts operational costs or equipment reliability.

Conclusion

The Omron G2RL series represents a mature, well-established relay platform that balances compact form factor with robust electrical performance and operational reliability. The series' multiple contact configurations, coil voltage options, and performance tiers enable designers to select specific variants that precisely match application requirements without over-specification or compromise. Comprehensive international standards compliance, proven mechanical durability, and flux-protective design establish the G2RL series as a dependable choice for applications ranging from consumer appliances to industrial control systems. The availability of PWM-capable variants addresses modern design requirements for power efficiency and thermal management, extending the relay's applicability to emerging applications in battery-powered and energy-constrained systems.

Frequently Asked Questions (FAQ)

Q1. What distinguishes the G2RL series from earlier Omron relay generations?

A1. The G2RL series introduces a low-profile design with maximum height of 15.7 mm compared to earlier models, enabling integration into miniaturized equipment. The series incorporates flux-protective sealing as standard, eliminating post-manufacturing cleaning requirements. Additionally, the availability of PWM-capable variants (-PW1 models) enables power consumption reduction during the relay holding phase, addressing modern design requirements for energy efficiency.

Q2. How does the contact form selection affect G2RL series relay application?

A2. The G2RL series offers SPST-NO, SPDT, DPST-NO, and DPDT contact configurations. SPST-NO variants provide single-circuit switching suitable for simple on-off control. SPDT variants enable switching between two independent circuits with a single relay. DPST-NO variants provide two independent normally-open contacts for simultaneous switching of two loads. DPDT variants enable coordinated switching of multiple loads with simultaneous opening and closing of different contact pairs. Selection depends on the specific circuit topology and control requirements.

Q3. What performance tier should be selected for applications with elevated switching currents?

A3. The G2RL series offers three performance tiers: standard type (8 A at 250 VAC), high-capacity type (16 A at 250 VAC), and high-sensitivity type (10 A at 250 VAC). Applications with switching currents approaching or exceeding 8 A should specify high-capacity variants to ensure adequate contact capacity and minimize contact erosion. High-capacity variants demonstrate 50,000 operations at rated load compared to 30,000 operations for standard variants, providing extended service life in demanding applications.

Q4. How does the PWM control feature in -PW1 variants reduce power consumption?

A4. The -PW1 variants enable voltage reduction to 55% of rated voltage after the initial 100 millisecond energization period. This holding voltage reduces power consumption from approximately 400 mW to approximately 120 mW, representing a 70% reduction. The strategy maintains contact closure while minimizing thermal generation and battery drain. This approach proves particularly valuable in battery-powered equipment, automotive applications, and systems where continuous relay energization would generate excessive heat.

Q5. What temperature range should be specified for equipment operating in high-temperature industrial environments?

A5. Standard G2RL variants operate reliably from -40°C to 85°C ambient temperature. The -CV variants extend the upper operating limit to 105°C, accommodating high-temperature industrial environments. The -HA variants, designed for home appliance applications, also operate to 85°C. Selection of -CV variants requires verification that the specific contact configuration and coil voltage combination supports 105°C operation, as not all model variants offer this extended temperature capability.

Q6. How do the must-operate and must-release voltage specifications affect relay selection?

A6. The must-operate voltage (typically 10% of rated voltage for standard models) establishes the minimum voltage required for reliable contact closure. The must-release voltage (typically 70% of rated voltage) establishes the voltage level below which contacts return to the de-energized state. These specifications define the operating window for relay control circuits. In applications with variable supply voltages, designers must ensure that the supply voltage remains above the must-operate threshold during energization and falls below the must-release threshold during de-energization to prevent relay chatter or unreliable operation.

Q7. What environmental protection does the flux-protective design provide?

A7. The G2RL series incorporates flux-protective sealing with two designated sealing holes on the relay case. This design prevents flux residues from contaminating internal relay components during PCB manufacturing processes, eliminating the need for post-manufacturing cleaning procedures. The sealed design also provides resistance to moisture ingress and environmental contamination while allowing controlled venting of internal pressure differentials. This approach reduces manufacturing costs and improves reliability in applications where flux residues might otherwise compromise contact performance.

Q8. How do the dielectric strength specifications ensure isolation between control and load circuits?

A8. The G2RL series provides 5,000 VAC dielectric strength between coil and contacts, establishing robust isolation between the control circuit and the switched load. Between contacts of the same polarity, the dielectric strength measures 1,000 VAC. Between contacts of different polarity, the dielectric strength reaches 2,500 VAC. These specifications ensure that high-voltage transients in the load circuit cannot couple into the control circuit, protecting sensitive control electronics from damage. The 10 kV impulse withstand voltage (1.2 × 50 microsecond waveform) demonstrates additional protection against transient overvoltage events common in industrial environments.

Q9. What mechanical durability can be expected from G2RL series relays in continuous operation?

A9. The G2RL series demonstrates 20,000,000 mechanical operations at 18,000 operations per hour for standard models, representing approximately 1,111 hours of continuous operation at maximum switching frequency. High-capacity variants achieve 50,000 electrical operations at rated load (250 VAC, 16 A resistive), while standard variants achieve 30,000 operations under identical conditions. Actual service life depends on load type, switching frequency, and operating temperature. Resistive loads produce longer relay life compared to inductive or capacitive loads due to reduced contact erosion and arcing phenomena.

Q10. How should the G2RL series be specified for applications in explosive atmospheres?

A10. Specific G2RL variants meet IEC/EN 60079-1 and IEC/EN 60079-15 standards for equipment used in explosive atmospheres. These standards establish requirements for enclosed-break devices (Group IIA) and sealed devices. Group IIA classification encompasses hydrogen-air mixtures at 55% ± 0.5% concentration, covering applications in chemical processing and petroleum refining. Designers must specify variants explicitly certified for explosive atmosphere use and verify that the specific model variant, contact configuration, and coil voltage combination carries the required certification. Contact Omron representatives for detailed information regarding explosive atmosphere applications.

Q11. What coil voltage rating should be selected for typical industrial control applications?

A11. Industrial control applications most commonly utilize 12 VDC or 24 VDC coil voltages. The 12 VDC rating provides compatibility with automotive and industrial control systems using 12V supply buses. The 24 VDC rating represents the standard industrial control voltage in most manufacturing environments. The 5 VDC rating accommodates low-voltage logic circuits and battery-powered applications. The 48 VDC rating serves specialized applications in telecommunications and high-voltage industrial systems. Selection should align with the available control circuit supply voltage to minimize the need for additional voltage conversion circuits.

Q12. How do contact material specifications affect relay performance in different load environments?

A12. The G2RL series utilizes silver-alloy contact material with cadmium-free composition, meeting environmental regulations while maintaining reliable electrical contact characteristics. Silver-alloy contacts provide excellent electrical conductivity and resistance to corrosion, ensuring stable contact resistance below 100 mΩ throughout the relay's service life. The cadmium-free composition eliminates environmental and health hazards associated with cadmium exposure. The -ASI variants substitute AgSnIn (silver-tin-indium) contact material for specialized applications requiring enhanced performance in specific load environments. Contact material selection affects contact erosion rates, arcing characteristics, and long-term reliability in different electrical load conditions.

Q13. What precautions should be observed when using G2RL series relays in corrosive gas environments?

A13. The G2RL series should not be used in atmospheres containing corrosive gases such as sulfuric acid vapor or organic gases. Corrosive gas exposure causes contact surface corrosion, leading to connection failure and functional faults. Applications in corrosive environments require either sealed relay variants with enhanced protection or alternative switching technologies. Designers should consult Omron representatives regarding sealed model availability and suitability for specific corrosive gas environments before specifying the G2RL series for such applications.

Q14. How should the G2RL series be integrated into circuits requiring surge protection?

A14. The G2RL series incorporates internal surge absorption through diode networks in the coil circuit. External surge protection may be required depending on the specific application and load characteristics. Inductive loads generate voltage transients when the relay contacts open, potentially damaging the relay coil or control circuit electronics. Designers should implement external surge suppression using diodes, varistors, or RC networks across inductive loads to limit transient voltage magnitudes. The relay's 10 kV impulse withstand voltage provides protection against moderate transient events, but severe transients require external suppression to ensure reliable long-term operation.

Q15. What mounting considerations apply when integrating G2RL series relays into PCB designs?

A15. The G2RL series employs through-hole mounting with 1.3 mm diameter mounting holes. Different model variants feature varying numbers of mounting holes—ranging from four to eight holes depending on contact configuration—to accommodate different electrical topologies. The relay exhibits no coil polarity requirement, simplifying installation and reducing assembly errors. Terminal spacing of 4.6 mm between adjacent pins facilitates standard PCB trace routing. The 29 mm by 12.7 mm footprint enables compact PCB layouts while maintaining adequate spacing for manufacturing tolerances and electrical isolation requirements. Designers should verify mounting hole locations and terminal arrangements for specific model variants before finalizing PCB layouts.