Aviation Relay JRW-212MA TO-5: Replacement for Deutsch TSS Series & Teledyne 412DD Series with Military Grade Metal Design
Product Overview
The JRW-212MA TO-5 is a premium Military Metal Sealing Relay specifically engineered as a direct form-fit-function replacement for legacy Deutsch TSS Series and Teledyne 412DD Series relays. This high-performance Aviation DC Relay combines heritage compatibility with modern manufacturing excellence, providing a reliable upgrade path for aging aerospace and military systems. With its military-grade metal TO-5 package and enhanced performance characteristics, it serves as an ideal replacement component for Aircraft Engine controls, avionics systems, and other critical applications where Deutsch TSS or Teledyne 412DD components are specified.
Product Features & Advantages
The JRW-212MA TO-5 offers significant advantages as both a direct replacement and performance-enhanced solution for legacy systems:
- Direct Heritage Compatibility: Form-fit-function replacement for Deutsch TSS Series and Teledyne 412DD Series relays with identical mechanical and electrical interfaces.
- Enhanced Military-Grade Construction: Superior Military Metal Relay design with improved materials and manufacturing processes compared to aging original components.
- Advanced Hermetic Sealing: TO-5 metal-can hermetic sealing provides better environmental protection than many original designs, ensuring reliable operation in harsh aerospace conditions.
- Improved Electrical Performance: Lower contact resistance (≤50mΩ initial), faster switching (≤4ms action/release), and enhanced reliability characteristics.
- Dual Load Capability: Maintains ability to handle both standard power loads (1A at 28V DC) and sensitive low-level signals (10-50µA at 10-50mV).
- Extended Temperature Range: Operates reliably from -65°C to +125°C, suitable for extreme aerospace environmental conditions.
- Weight-Optimized TO-5 Package: Standard TO-5 footprint weighing under 3 grams, maintaining compatibility while offering potential weight advantages.
- Modern Material Compliance: Materials compliant with current RoHS and environmental regulations, unlike some legacy components.
This replacement relay complements YM's comprehensive portfolio of Military Electromagnetic Relay solutions, manufactured to the same rigorous standards as our Aviation Latching Relay and Sealed magnetic Latching Relay product families.
Technical Specifications
Complete performance parameters showing compatibility with and improvements over Deutsch TSS and Teledyne 412DD specifications:
Electrical Specifications
- Coil Voltage: Compatible with original TSS/412DD voltage specifications (typically 27V DC)
- Contact Configuration: Matches original TSS/412DD contact arrangements
- Contact Rating:
- Standard Load: 1A at 28V DC (minimum 100,000 cycles)
- Low-Level Signal: 10-50 µA at 10-50 mV
- Coil Power Consumption: 0.3W to 0.43W (compatible or improved vs originals)
- Contact Resistance:
- Initial Value: ≤ 50 mΩ
- After Life Testing: ≤ 200 mΩ
Performance Characteristics
- Switching Speed:
- Action Time: ≤ 4 milliseconds
- Release Time: ≤ 4 milliseconds
- Operational Life: Minimum 100,000 cycles at rated load
- Dielectric Strength:
- Normal Conditions: 500 Vr.m.s., 50Hz
- High Altitude: 250 Vr.m.s., 50Hz
- Insulation Resistance: > 500 MΩ (initial measurement)
Physical & Environmental Specifications
- Package: TO-5 metal can (hermetic sealing)
- Sealing Performance: Leakage Rate ≤ 1.0 × 10⁻³ Pa·cm³/s
- Weight: < 3 grams
- Operating Temperature: -65°C to +125°C
- Dimensions: Compatible with Deutsch TSS and Teledyne 412DD footprints
Replacement Implementation Guidelines
Follow these steps for successful replacement of Deutsch TSS or Teledyne 412DD relays:
- Original Component Identification: Confirm the specific Deutsch TSS or Teledyne 412DD part number being replaced.
- Compatibility Verification: Cross-reference electrical and mechanical specifications using our compatibility charts.
- System Assessment: Evaluate the operating conditions and failure history of the original components in your system.
- Sample Testing: Test JRW-212MA samples in your specific application to verify performance and compatibility.
- Documentation Update: Update maintenance manuals and parts lists to reflect the replacement component.
- Qualification Support: Utilize our technical data packages to support any required requalification processes.
Application Scenarios
The JRW-212MA TO-5 serves as a direct replacement in these critical systems originally designed with Deutsch TSS or Teledyne 412DD components:
- Legacy Aircraft Avionics: Flight control systems, navigation equipment, and cockpit instrumentation in older commercial and military aircraft.
- Aircraft Engine Control Systems: Engine monitoring, fuel control, and ignition systems in legacy Aircraft Engine management systems.
- Military Communication Equipment: Secure communication systems, radar interfaces, and electronic warfare platforms.
- Industrial Control Systems: Where original TSS/412DD components were specified for harsh environment applications.
- Test & Measurement Equipment: Calibration systems, automated test equipment, and laboratory instrumentation.
- Marine & Naval Systems: Shipboard electronics and naval communication systems originally using these component series.
Value Proposition for Legacy System Support
The JRW-212MA TO-5 delivers significant value for organizations maintaining legacy systems:
- Extended System Lifecycle: Enables continued operation of valuable legacy equipment by providing reliable replacement components.
- Improved Reliability: Modern manufacturing and materials often provide enhanced reliability over aging original components.
- Supply Chain Security: Provides stable sourcing alternative for components that may be obsolete or difficult to source.
- Cost-Effective Maintenance: More affordable than sourcing original components on the secondary market or redesigning systems.
- Performance Enhancement Potential: May offer improved performance characteristics while maintaining compatibility.
- Complete Documentation: Full modern technical documentation compared to incomplete or lost original documentation.
Certifications & Compliance
The JRW-212MA TO-5 is designed to meet or exceed original specifications while incorporating modern standards:
- Performance equivalent or superior to original Deutsch TSS and Teledyne 412DD specifications
- Manufactured under modern quality management systems with full traceability
- Materials compliance with current RoHS environmental directives
- Testing validation for aerospace and military environmental conditions
- Documentation supporting legacy system maintenance and requalification
- Compatibility with original qualification data where required
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Customization for Specific Replacement Needs
YM offers tailored solutions for specific legacy system requirements:
- Voltage Matching: Custom coil voltages to match specific legacy system requirements
- Pin Configuration Modifications: Adjusted layouts for specific interface requirements
- Enhanced Environmental Performance: Special sealing for extreme operating conditions
- Testing & Documentation Packages: Custom testing protocols and documentation for specific requalification processes
- Marking & Identification: Custom markings to match original component identification systems
- Lot Traceability: Enhanced traceability documentation for critical legacy system support
Production Process & Quality Assurance
Each JRW-212MA TO-5 relay undergoes rigorous manufacturing and testing to ensure replacement reliability:
- Material Selection & Verification: Components sourced from qualified suppliers with material property verification.
- Precision TO-5 Manufacturing: Critical components manufactured to exact tolerances for dimensional compatibility.
- Controlled Assembly: Assembly in controlled environments ensuring compatibility with original designs.
- Hermetic Sealing Process: Advanced sealing techniques ensuring environmental protection meets or exceeds originals.
- Comprehensive Testing: 100% electrical testing plus environmental and life testing validation.
- Compatibility Verification: Testing against original TSS/412DD specifications to ensure proper replacement function.
Comparison with Original Components
Key advantages of the JRW-212MA as a replacement solution:
- Manufacturing Quality: Modern manufacturing processes and quality controls enhance consistency and reliability.
- Material Improvements: Contemporary materials with improved performance and environmental characteristics.
- Documentation: Complete technical documentation compared to often incomplete legacy documentation.
- Supply Chain Stability: Consistent manufacturing and supply compared to sporadic availability of original components.
- Environmental Compliance: Materials compliant with modern environmental regulations.
- Technical Support: Full manufacturer support including application engineering and failure analysis.
Frequently Asked Questions (FAQ)
Q1: Is the JRW-212MA TO-5 a direct drop-in replacement for all Deutsch TSS and Teledyne 412DD relays?
A: The JRW-212MA TO-5 is designed as a form-fit-function replacement for specific variants within these series. We provide detailed cross-reference charts and recommend verifying compatibility with your specific part numbers. Our technical team offers direct compatibility assessment support.
Q2: What documentation is available to support replacement qualification?
A: We provide comprehensive technical data packages including specifications, test reports comparing performance to original components, material certifications, and application notes specifically addressing replacement considerations for legacy systems.
Q3: Can this relay be used in new designs as well as replacement applications?
A: Absolutely. While designed as a replacement, the JRW-212MA TO-5 offers excellent performance for new designs requiring the TO-5 package format and military-grade reliability. It can serve as a modern alternative to specifying obsolete component series in new systems.
Q4: How does the JRW-212MA compare to NOS (New Old Stock) original components?
A: The JRW-212MA typically offers more consistent quality (modern manufacturing vs aging NOS), better documentation, and materials compliant with current regulations. NOS components may have degraded due to age, while our relays are freshly manufactured with controlled processes.
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