JZC‑1M RG4.553.060G Military DPDT Relay – Direct Replacement for HFW 5C, P3C47 (RES‑47), 24V
Product Overview
The JZC‑1M RG4.553.060G is a hermetically sealed, military‑grade Military Metal Relay designed as a direct form‑fit‑function replacement for obsolete relays such as HFW 5C, P3C47 (RES‑47), and other 24V DPDT aerospace types. This Metal Sealing Relay features a rugged DPDT (2 Form C) contact configuration, ultra‑low coil power consumption (0.3–0.43W), and fast operate/release time (≤4ms). With a glass‑to‑metal sealed construction (leakage ≤10⁻³ Pa·cm³/s), it withstands moisture, fuel vapors, altitude changes, and high vibration environments. Ideal for aviation, drone, aircraft engine, and train applications, the JZC‑1M meets MIL‑PRF‑39016 requirements. As a core product in YM’s relay portfolio – which includes Polarized Relay, Latching Relay, PCB Board Relay, Automotive Relay, and Industrial Power Relay – the JZC‑1M delivers uncompromised reliability for critical aerospace and defense systems.
Technical Specifications
Coil Parameters (24V / 28V DC)
- Nominal coil voltage: 24V DC (compatible with 28V aircraft systems)
- Coil power consumption: (0.3–0.43)W – ultra‑low for a DPDT Military Relay
- Pick‑up voltage (max): 75% of nominal
- Drop‑out voltage (min): 10% of nominal
- Coil resistance (at 25°C): Approx. 1300–1900Ω (24V version)
Contact Ratings (DPDT – 2 Form C)
- Maximum switching current (resistive): 1A at 28V DC (reference test condition)
- Low level switching capability: (10–50)μA, (10–50)mV – 1×10⁵ operations, ideal for dry circuits
- Initial contact resistance: ≤50mΩ; after life test ≤200mΩ
Timing & Isolation
- Action time (operate): ≤4ms (typical ≤3ms)
- Release time: ≤4ms
- Dielectric strength (normal atmosphere): 500Vr.m.s., 50Hz between contacts and case; under low pressure: 250Vr.m.s.
- Insulation resistance (normal atmosphere): >500MΩ at 500V DC; after high‑level life test: >50MΩ
Mechanical & Environmental (Military Grade)
- Weight: <3g – ultra‑light for airborne use
- Sealing (leakage rate): ≤10⁻³ Pa·cm³/s (hermetic, glass‑to‑metal seal)
- Operating temperature range: -65°C to +125°C
- Shock & vibration: Withstands 50g, 6ms half‑sine; 10‑2000Hz, 20g random vibration per MIL‑STD‑810
- Terminal style: 8‑pin (DPDT) – solder hook or PCB through‑hole (gold‑plated)
- Part number equivalents: HFW 5C, P3C47 (RES‑47), RG4.553.060G
All parameters are validated at 25°C ambient. The JZC‑1M meets MIL‑PRF‑39016 and is form‑fit‑function compatible with HFW 5C, P3C47, and similar relay types.
Key Features & Advantages – Direct HFW 5C Replacement
- Direct replacement for HFW 5C, P3C47 (RES-47): Exact pinout, mounting dimensions, and electrical ratings – no redesign for legacy systems. Solves obsolescence issues.
- Hermetic metal sealing (≤10⁻³ Pa·cm³/s): Glass‑to‑metal seal protects against moisture, salt spray, fuel vapors, and altitude changes – ensures reliable operation in unpressurized aircraft bays and engine compartments.
- Ultra‑low coil power (0.3–0.43W): Allows direct drive from avionics logic (24V/28V), reduces heat generation and power supply load – ideal for battery‑backed drones and portable equipment.
- Fast switching (≤4ms) & high isolation: 500Vrms dielectric strength and >500MΩ insulation prevent crosstalk in mixed‑signal environments – essential for PCB Board Relay and PCB Signal Relay designs.
- Wide temperature & vibration tolerance: -65°C to +125°C and 20g vibration meet RTCA/DO‑160 and MIL‑STD‑810 – suitable for fighter jets, helicopters, drones, and railway rolling stock.
- Excellent low‑level signal switching: Gold‑plated contacts reliably switch down to 10μA / 10mV – perfect for sensor multiplexing, avionics I/O, and mission computers.
YM’s engineering advantage: The JZC‑1M leverages advanced magnetic circuit technology from our Latching relay and Polarized Relay families, ensuring consistent contact force and minimal bounce. As a true Military Metal Relay , it outperforms legacy HFW 5C relays in contact life and hermeticity. For complete avionics and drone systems, YM also offers Aviation Microswitch, Aviation Rocker Switch, and Military Aviation Connector – a one‑stop solution for defense contractors.
How to Use the JZC-1M (HFW 5C Replacement) – Step by Step
- Verify pinout compatibility: Compare the JZC‑1M pinout diagram (DPDT, 8‑pin) with your existing HFW 5C or P3C47 relay – they are identical. Check coil voltage (24V) and contact ratings.
- Remove old relay: Desolder or unplug the existing HFW 5C relay from the PCB or socket. Clean the pads with isopropyl alcohol.
- Install JZC‑1M: Insert the new relay into the socket or PCB holes. Ensure correct orientation (pin 1 indicator).
- Solder (if PCB mount): Use 60/40 rosin‑core solder, iron temperature ≤260°C, duration ≤5 seconds per pin. Avoid flux ingress – use no‑clean flux.
- Coil drive: Apply +24V DC (or +28V) to the coil pins (observe polarity). The relay will energize when voltage exceeds 18V (75% of nominal). For inductive loads, add a flyback diode across the coil.
- Functional test: Apply coil voltage and measure contact resistance across each closed contact pair – should be ≤50mΩ. De‑energize and verify insulation >10MΩ between open contacts.
Pro tip for avionics integrators: For fail‑safe designs, use one pole to switch the main signal and the second pole to provide a status feedback. The JZC‑1M’s DPDT configuration saves space compared to two SPDT relays.
Application Scenarios & Key Buyer Benefits
Typical Military & Aerospace Applications
- Legacy aircraft modernization: Replace obsolete HFW 5C / P3C47 relays in C‑130, F‑16, Black Hawk, and other platforms – improves reliability without wiring changes.
- Drone flight control computers: Discrete I/O expansion, autopilot mode selection, and payload release – lightweight and hermetically sealed.
- Engine management (aircraft, train, marine): Fuel shutoff valves, ignition control, and overspeed protection – wide temperature range.
- Radar & electronic warfare (EW) systems: Signal routing and antenna switching – low contact resistance ensures minimal signal loss.
- Ground support equipment (GSE): Generator field control, battery charger contactors, and test stand power switching – durable for field use.
Direct Value to International Buyers (Defense OEMs, MROs, UAV Manufacturers)
- Eliminate obsolescence: Direct drop‑in replacement for HFW 5C, P3C47 – ensures continued operation of legacy systems.
- Reduced lifecycle cost: Hermetic sealing and low coil power reduce field failures and power consumption – lowers total ownership cost.
- Simplified logistics: One JZC‑1M replaces multiple legacy part numbers – reduces spare parts inventory.
- Global compliance: MIL‑PRF‑39016 qualified, RoHS/REACH compliant, with AS9100D manufacturing – ready for FMS and direct defense contracts.
For large‑scale upgrades, YM offers pre‑qualified drop‑in kits including relay, socket, and mounting hardware. Engineering samples available for qualification testing.
Certifications & Compliance
- MIL-PRF-39016 (hermetic, signal relay) – qualification data available.
- 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 & REACH compliant – full material declaration available.
Each JZC‑1M relay is 100% tested for coil resistance, pick‑up/drop‑out voltage, contact resistance (each pole), 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 JZC‑1M variants for specific military, aerospace, and industrial programs. Volume orders can include:
- Coil voltage: 5V, 12V, 24V, 28V, 48V DC – customized to match platform power buses.
- Contact material: Gold overlay (standard for low‑level), silver‑cadmium oxide (1A power), or rhodium (ultra‑low level).
- Terminal style & finish: Solder hook, straight DIP, or surface‑mount; gold or tin plating.
- 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 cross‑reference to HFW 5C / P3C47. 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 the most stringent requirements for aerospace and defense programs.
- Raw 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.
- Contact assembly in Class 100 cleanroom: Alignment of DPDT contacts under 40x microscope; dynamic contact force testing 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 all parameters per MIL‑PRF‑39016.
- Destructive Physical Analysis (DPA): One unit per lot cross‑sectioned per MIL‑STD‑1580 for internal workmanship.
With decades of experience in Metal Sealing Relay and PCB Signal Relay production, YM has supplied relays to major defense contractors and aerospace primes. The JZC‑1M RG4.553.060G is built to exceed the reliability of original HFW 5C relays, ensuring long‑term support for legacy and next‑generation platforms.
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