Aviation JK2-1 Military Relay 28V 20A

Product Overview

The JK2-1 Military Relay is a high-power, hermetically sealed relay designed for demanding aviation, drone, and railway applications. Rated at 28V DC / 20A resistive load, this Military Grade Switch (relay) provides robust switching for aircraft engines, flight control actuators, drone power distribution, and train lighting systems. Featuring ultra-low coil power consumption (0.3–0.43W), fast operate/release time (≤4ms), and excellent dielectric strength (500Vrms), the JK2-1 ensures reliable performance under extreme temperatures (-55°C to +85°C), high vibration, and altitude pressure changes. Its glass-to-metal sealed construction guarantees leakage rate ≤10⁻³ Pa·cm³/s, protecting internal contacts from moisture, salt spray, and dust. As a core product in YM’s aviation relay portfolio – which includes Aircraft Rocker Switches, aviation switch with Military Grade, Military Rocker Aviation Switch, Aircraft Swing Arm Switch, and Micro switch – the JK2-1 delivers uncompromised power switching for mission-critical systems.

Technical Specifications

Coil Parameters (28V DC)

• Nominal coil voltage: 28V DC (compatible with 24V/28V aircraft systems)
• Coil power consumption: (0.3–0.43)W – ultra-low for a 20A relay
• Pick-up voltage (max): 75% of nominal
• Drop-out voltage (min): 10% of nominal
• Coil resistance: Approx. 1800–2600Ω at 25°C

Contact Ratings (20A High Power)

• Maximum switching current: 20A at 28V DC (resistive load)
• Motor load rating: 10A at 28V DC (inductive)
• Low level switching capability: (10–50)μA, (10–50)mV – 1×10⁵ operations
• Reference resistive load: 1A, 28V DC, 1×10⁵ operations
• Initial contact resistance: ≤50mΩ; after life test ≤200mΩ

Timing & Dielectric

• Action time (operate): ≤4ms (typical ≤3ms)
• Release time: ≤4ms
• Dielectric strength (normal atmosphere): 500Vr.m.s., 50Hz between contacts and case; under low pressure (drone altitude): 250Vr.m.s.
• Insulation resistance (normal atmosphere): >500MΩ; after high-level life test: >50MΩ

Mechanical & Environmental (Military Grade)

• Weight: <3g – ultra-light for airborne equipment
• Sealing (leakage rate): ≤10⁻³ Pa·cm³/s (hermetic, glass-to-metal seal)
• Operating temperature range: -55°C to +85°C (extended -65°C to +125°C optional)
• Shock & vibration: Withstands 50g, 6ms half-sine; 10-2000Hz, 20g random vibration per RTCA/DO-160
• Terminal style: Solder hook or PCB through-hole (gold-plated)

All parameters are validated at 25°C ambient. The JK2-1 meets MIL-PRF-39016 requirements for hermetically sealed power relays.

Product Images & Visuals

Above: JK2-1 series military relay (hermetic metal can). Contact YM for dimensional outline, pin configuration, and environmental qualification reports.

Key Features & Advantages for Aviation, Drone & Train Applications

• High power switching (20A @ 28V DC): Capable of handling engine starter solenoids, actuator motors, and high-intensity lighting – ideal for aircraft and heavy-duty equipment.
• Ultra-low coil power (0.3–0.43W): Reduces heat generation and allows direct drive from avionics logic (e.g., 28V TTL/CMOS) – minimizes power supply load.
• Hermetic metal sealing (≤10⁻³ Pa·cm³/s): Glass-to-metal seal protects contacts from moisture, salt spray, and altitude pressure changes – ensures reliable operation in unpressurized drone bays and engine compartments.
• Fast switching (≤4ms) & high isolation: 500Vrms dielectric strength and >500MΩ insulation prevent crosstalk and arc-over in high-voltage circuits.
• Wide temperature & vibration tolerance: -55°C to +85°C operation and 20g vibration meet RTCA/DO-160 and MIL-STD-810 requirements – suitable for drone swarms and railway rolling stock.
• Low contact resistance & long life: ≤50mΩ initial resistance and 1×10⁵ electrical cycles at rated load – reduces maintenance frequency.

YM’s engineering advantage: The JK2-1 leverages advanced magnetic circuit technology from our Military Rocker Aviation Switch and certified aircraft rocker switches families, scaled for high-current loads. Compared to commercial relays, this Military Grade Relay offers true hermeticity and extended life, making it the preferred choice for mission-critical power distribution. For complete control systems, YM also offers Aviation Rocker Switch with military grade, military grade rotary switches, aviation encoding switch with military grade, and gx Aviation Connector – a one-stop solution for aircraft, drone, and train power management.

How to Use the JK2-1 Military Relay – Step by Step

1. Identify coil and contact pins: The JK2-1 typically has two coil pins (positive and negative) and two or four contact pins (common, NO, NC). Refer to the datasheet for exact pinout (TO-5 or similar base).
2. Apply coil voltage: Connect +28V DC to the coil+ pin and ground to coil- pin. The relay will energize when voltage exceeds 21V (75% of nominal). For inductive loads, add a flyback diode across the coil.
3. Load connection: Connect the power source to the common terminal and the load (e.g., engine starter, drone motor controller) to the normally-open (NO) terminal. When energized, the load receives power.
4. Arc suppression (for inductive loads): For motor or solenoid loads, install a snubber (RC network) or a diode across the load contacts to extend relay life.
5. PCB mounting: Solder the relay into a socket or directly onto the PCB. Use a heat sink during soldering (max 260°C for 5 seconds). Avoid flux ingress – use no-clean flux.
6. Functional test: Apply coil voltage and measure voltage drop across the closed contacts – should be <100mV at 20A. De-energize and verify insulation resistance >10MΩ between open contacts.

Pro tip for system integrators: For drone flight termination systems (FTS), use the JK2-1 in a normally-closed configuration to cut power when de-energized, providing fail-safe operation. YM can provide custom mounting brackets and pre-wired harnesses.

Application Scenarios & Key Buyer Benefits

Typical Military & Commercial Uses

• Aircraft engine control: Starter relay, ignition power, and fuel shutoff valves – 20A rating handles high inrush currents.
• Drone power distribution: Main battery switching, payload power, and flight controller isolation – lightweight and sealed for UAVs.
• Train & railway systems: Lighting control, door actuators, and auxiliary power – vibration-resistant and wide temperature range.
• Ground support equipment (GSE): Generator contactors, hydraulic pump relays, and battery chargers – durable for field environments.
• Military vehicles & naval systems: Turret power, communication equipment, and weapon system relays – hermetically sealed for harsh conditions.

Direct Value to International Buyers (Defense OEMs, UAV Manufacturers, Railway Integrators)

• Improved system reliability: Hermetic sealing eliminates contact oxidation failures – reduces field returns and unscheduled maintenance.
• Reduced power consumption: Ultra-low coil power (0.43W max) lowers heat generation and extends battery life in drones and electric aircraft.
• Simplified logistics: The JK2-1 is form-fit-function compatible with many legacy military relays (e.g., Teledyne, CII) – reduces requalification costs.
• Global compliance: MIL-PRF-39016 qualified, RoHS/REACH compliant, with AS9100D manufacturing – ready for FMS and direct defense contracts.

For new aircraft or drone programs, YM offers customization of coil voltages, contact materials, and mounting configurations. Engineering samples available for qualification testing.

Certifications & Compliance

• MIL-PRF-39016 (hermetic, power relay) – qualification data available upon request.
• RTCA/DO-160G (environmental conditions for airborne equipment): tested for temperature/altitude, vibration, humidity, and salt spray.
• MIL-STD-810G (environmental – shock, vibration, temperature extremes).
• ISO 9001:2015 & AS9100D certified manufacturing (aerospace quality management).
• RoHS 2011/65/EU & REACH (EC 1907/2006) compliant – full material declaration.
• Hermeticity: 100% tested per MIL-STD-883, method 1014 – leak rate ≤10⁻³ Pa·cm³/s.

Each production lot is 100% inspected for coil resistance, pick-up/drop-out voltage, contact resistance at 20A, dielectric strength, and insulation resistance. Sample relays undergo destructive physical analysis (DPA) per MIL-STD-1580. Certificates of Conformance (CoC) and test data are provided with every shipment.

Customization Options

YM supports tailored JK2-1 variants for specific aircraft, drone, and train platforms. Volume orders can include:

• Coil voltage: 12V, 24V, 28V, 48V DC – customized to match vehicle power bus.
• Contact material: Silver-cadmium oxide (standard, 20A), gold-plated (low-level), or tungsten (high-inrush).
• Terminal style & finish: Solder hook, straight DIP, or surface-mount; gold or tin plating.
• Sealing enhancement: Additional internal getter for hydrogen-sensitive environments (space/avionics).
• Screening level: Commercial (standard), high-reliability (100% burn-in, temperature cycling), or space-level (DPA, radiation testing).
• Marking: Laser engraving of customer part number, date code, or inspection stamp.

Our engineering team provides application support, including thermal derating curves, driver circuit recommendations, and SPICE models. Minimum order quantities for custom variants apply – contact YM with your requirements.

Production Process & Quality Assurance (AS9100D Certified)

YM’s military relay production line follows a zero-defect, fully traceable process designed to meet AS9100D and the most stringent customer requirements for aerospace and defense programs.

• Incoming material control: 100% verification of magnetic alloys, contact wires, glass preforms, and metal cans – all from approved aerospace suppliers with COC and batch traceability.
• Coil winding & encapsulation: Precision winding with automated tension control; vacuum encapsulation using low-outgassing epoxy (NASA outgassing compliant).
• Contact assembly in Class 100 cleanroom: Alignment of contacts under 40x microscope; dynamic contact force measurement to ensure ≤50mΩ initial resistance.
• Hermetic sealing & leak detection: Resistance welding in dry nitrogen atmosphere; 100% helium mass spectrometry leak test (sensitivity 10⁻⁹ Pa·cm³/s).
• Environmental screening (100% for high-rel lots): Thermal shock (-65°C to +125°C, 10 cycles), constant acceleration (10,000g), and burn-in (168 hours at 125°C with periodic operation).
• Final electrical test: Automated test system (ATS) measures pick-up/drop-out voltage, operate/release time, contact bounce, dynamic contact resistance at 20A, and insulation resistance at 500VDC.
• Destructive Physical Analysis (DPA): One unit per lot is cross-sectioned and examined per MIL-STD-1580 for internal workmanship.

With decades of experience in military grade switch and aviation encoding switch manufacturing, YM has supplied relays to major defense contractors, drone manufacturers, and railway integrators. The JK2-1 is built to exceed the reliability expectations of next-generation aircraft, UAV swarms, and high-speed trains.