Aviation Sealed Relay JZC-1M RG4.553.032G

Product Overview

The JZC-1M RG4.553.032G is a hermetically sealed, high‑reliability DPDT 2C (double‑pole double‑throw) Military Metal Relay designed for demanding aerospace, defense, and industrial applications. This Metal Sealing Relay offers robust switching for aircraft flight controls, drone power distribution, engine management systems, railway signaling, and ground support equipment. Rated for 5A at 28V DC resistive load and capable of switching low‑level signals down to 10μA/10mV, the JZC‑1M features ultra‑low coil power consumption (0.3–0.43W), fast operate/release time (≤4ms), and high insulation resistance (>500MΩ). Its glass‑to‑metal sealed construction guarantees leakage ≤10⁻³ Pa·cm³/s, protecting internal contacts from moisture, fuel vapors, and altitude pressure changes. As a core member of YM’s relay portfolio – which includes Polarized Relay, Latching Relay, PCB Board Relay, Automotive Relay, and Industrial Power Relay – the JZC‑1M delivers uncompromised performance for mission‑critical systems in military aircraft, drones, trains, and high‑reliability industrial controls.

Technical Specifications

Coil Parameters (Nominal 27V DC)

• Coil power consumption: (0.3–0.43)W – ultra‑low for a DPDT power relay
• Nominal coil voltage: 27V DC (compatible with 28V aircraft systems)
• Pick‑up voltage (max): 75% of nominal
• Drop‑out voltage (min): 10% of nominal
• Coil resistance (at 25°C): Approx. 1700–2400Ω

Contact Ratings (DPDT 2 Form C)

• Maximum switching current: 5A at 28V DC (resistive); 2A at 115V AC 400Hz
• Low level switching capability: (10–50)μA, (10–50)mV – 1×10⁵ operations
• Reference resistive load (test): 1A, 28V DC, 1×10⁵ operations
• 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 – lightweight 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: Solder hook or PCB through‑hole (gold‑plated)

All parameters are validated at 25°C ambient. The JZC‑1M meets MIL‑PRF‑39016 requirements for hermetically sealed relays.

Product Images & Visuals

Above: JZC-1M series relay – physical view, specification sheet, dimensional drawing, and performance curves. Contact YM for full datasheet and qualification reports.

Key Features & Advantages for Military Aviation

• DPDT 2C (double-pole double-throw) configuration: Two independent changeover contacts allow simultaneous switching of two circuits – ideal for redundant flight control channels or dual load management.
• 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, engine compartments, and outdoor shelters.
• Ultra‑low coil power (0.3–0.43W): Minimizes heat generation and allows direct drive from avionics logic (e.g., 28V CMOS) – reduces power supply load and thermal management requirements.
• Fast switching (≤4ms) & high isolation: 500Vrms dielectric strength and >500MΩ insulation prevent crosstalk and arc‑over in mixed‑signal environments.
• Wide temperature & vibration tolerance: -65°C to +125°C and 20g vibration meet RTCA/DO‑160 and MIL‑STD‑810 – suitable for fighter jets, drones, helicopters, 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 commercial DPDT relays in hermeticity and vibration tolerance. For complete avionics and drone systems, YM also offers Aviation Button Switch, Aviation Rocker Switch, Military Aviation Connector, and Aviation Microswitch – a one‑stop solution for defense contractors.

How to Use the JZC-1M DPDT Relay – Step by Step

1. Identify pin configuration: The JZC‑1M has 8 pins (DPDT). Refer to the datasheet pinout diagram (coil pins, common, NO, NC for each pole).
2. Apply coil voltage: Connect +27V DC to the coil+ pin and ground to coil- pin. The relay will energize when voltage exceeds 20.25V (75% of nominal). For inductive loads, add a flyback diode across the coil.
3. Load connection: Connect your circuits to the common (C) and normally‑open (NO) or normally‑closed (NC) terminals of each pole. Typical use: power to NO, signal to NC.
4. Arc suppression (for inductive loads): For motors or solenoids, install a snubber (RC network) 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 each closed contact pair – should be <100mV at 5A. 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 power and the second pole to provide a status signal to the flight computer – the DPDT configuration saves space and weight.

Application Scenarios & Key Buyer Benefits

Typical Military & Aerospace Applications

• Aircraft flight control systems: Autopilot actuator control, flap positioning, and trim motor switching – DPDT allows bidirectional motor control with a single relay.
• Drone power distribution & payload control: Battery isolation, camera power, and flight termination systems – lightweight and hermetically sealed for UAVs.
• Engine management (aircraft, train, marine): Fuel shutoff valves, ignition control, and overspeed protection – wide temperature tolerance.
• Radar & electronic warfare (EW) systems: Signal routing and antenna switching – low contact resistance ensures minimal signal loss.
• Railway & industrial control: Door actuators, lighting circuits, and braking systems – vibration‑resistant and long electrical life.

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

• Reduced system power & thermal load: Low coil power (0.43W max) reduces heat generation – allows denser packaging in avionics LRUs.
• Lower lifecycle cost: Hermetic sealing eliminates contact oxidation failures – reduces field returns and unscheduled maintenance.
• Simplified logistics: DPDT configuration replaces two SPDT relays – reduces component count and inventory.
• 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 screening levels. Engineering samples available for qualification testing.

Certifications & Compliance

• MIL-PRF-39016 (hermetic, signal and power 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 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 (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: 12V, 24V, 28V, 48V DC – customized to match platform power buses.
• Contact material: Gold overlay (standard for low‑level), silver‑cadmium oxide (5A power), or rhodium (ultra‑low level, <1μA).
• Terminal style & finish: Solder hook, straight DIP, or surface‑mount; gold or tin plating; weldable leads for hybrid microcircuits.
• 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 the most stringent 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 DPDT 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 for each pole, 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 Metal Sealing Relay and PCB Signal Relay production, YM has supplied relays to major defense contractors and aerospace primes. The JZC‑1M is built to exceed the reliability expectations of next‑generation military aircraft, drones, and high‑speed trains.