Aviation Metal Relay P3C54 27V with Durable Design
Product Overview
The P3C54 27V is a high-reliability Aviation Metal Relay featuring a durable design specifically engineered for demanding aerospace and defense applications. As part of the proven P3C series, this Military Metal Sealing Relay combines heritage compatibility with modern manufacturing excellence. The relay's robust construction and DPDT 8Pin configuration make it ideal for complex switching requirements in Aircraft Engine controls, drone flight systems, military communications, and other mission-critical applications where reliability cannot be compromised.
Product Features & Advantages
The P3C54 delivers exceptional performance through advanced engineering and durable construction, offering distinct advantages for military and aerospace applications:
- Durable Military-Grade Construction: Engineered with reinforced materials and design elements specifically for extended service life in harsh environments.
- DPDT Switching Capability: DPDT 8Pin 27V Relay configuration provides dual-circuit control in a single compact package, enabling complex switching functions.
- Enhanced Hermetic Sealing: Advanced metal-can sealing technology ensures complete protection against moisture, dust, and environmental contaminants.
- Superior Vibration & Shock Resistance: Designed to withstand extreme mechanical stress (30G+ vibration) encountered in military and aerospace operations.
- Extended Temperature Performance: Reliable operation across wide temperature ranges from -65°C to +125°C, suitable for diverse operational environments.
- Dual-Mode Operational Flexibility: Capable of handling both power loads (1A at 28V DC) and sensitive low-level signals (10-50µA at 10-50mV).
- Optimized Weight & Space Design: Compact form factor without mounting ears ("without ear" version) for space-constrained applications, weighing under 3 grams.
This relay represents YM's commitment to Military Electromagnetic Relay excellence, sharing manufacturing standards with our specialized Aviation Latching Relay and Sealed magnetic Latching Relay product lines.
Technical Specifications
Complete performance parameters for engineering evaluation and system design:
Electrical Specifications
- Rated Coil Voltage: 27V DC (Standard military/aviation voltage)
- Contact Configuration: DPDT (Double Pole Double Throw) - 8 pin configuration
- Contact Rating:
- Standard Resistive Load: 1A at 28V DC (minimum 100,000 cycles)
- Low-Level Signal Load: 10-50 µA at 10-50 mV
- Coil Power Consumption: 0.3W to 0.43W
- 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 Atmospheric Conditions: 500 Vr.m.s., 50Hz
- Low Pressure/High Altitude: 250 Vr.m.s., 50Hz
- Insulation Resistance: > 500 MΩ (initial measurement)
Physical & Environmental Specifications
- Sealing Performance: Leakage Rate ≤ 1.0 × 10⁻³ Pa·cm³/s
- Weight: < 3 grams
- Operating Temperature Range: -65°C to +125°C (standard military grade)
- Mounting Style: Available without mounting ears for compact PCB integration
- Package: Military-standard metal enclosure
System Integration Guidelines
For optimal performance with the P3C54 DPDT relay, follow these implementation steps:
- Circuit Design Analysis: Evaluate switching requirements to fully utilize DPDT capabilities for circuit simplification or redundancy.
- PCB Layout Planning: Design PCB with proper pin spacing and trace routing for the 8-pin configuration, considering both switched circuits.
- Coil Drive Circuit Design: Implement appropriate drive circuitry with protection elements for reliable coil operation.
- Thermal Management: Account for potential heat generation, especially when both poles are operated simultaneously at high loads.
- Mounting Considerations: For "without ear" versions, ensure secure PCB mounting with proper support and strain relief.
- System Testing Protocol: Develop comprehensive testing to verify both poles' operation under expected conditions.
Application Scenarios
The P3C54's DPDT configuration makes it particularly suitable for these critical applications:
- Aircraft Redundant Systems: Dual-circuit control for redundant avionics, backup systems, and fail-safe switching in flight control systems.
- Military Communications Equipment: Simultaneous switching of transmit/receive circuits, antenna selection, and mode switching in secure communications.
- Drone Flight Control Systems: Complex switching requirements in UAV flight controllers, payload management, and redundant power systems.
- Test & Measurement Equipment: Signal routing and switching in military test equipment and calibration systems.
- Industrial Control Systems: Where standard Industrial Power Relay solutions lack the required environmental protection or switching complexity.
- Legacy System Modernization: Replacement in existing systems requiring P3C series compatibility with DPDT functionality.
Value Proposition
The P3C54 DPDT relay delivers significant advantages to military and aerospace programs:
- Circuit Simplification: DPDT configuration reduces component count by replacing multiple SPST relays in many applications.
- Enhanced System Reliability: Military-grade construction and testing ensure dependable operation in critical systems.
- Space Optimization: Compact "without ear" design maximizes space utilization in densely packed electronic systems.
- Design Flexibility: DPDT functionality enables more sophisticated circuit designs with synchronized switching.
- Reduced System Complexity: Single component handles multiple switching functions, simplifying system design and maintenance.
- Lifecycle Cost Reduction: Extended service life and reduced component count lower total ownership costs.
Certifications & Compliance
The P3C54 is designed to meet rigorous military and aerospace standards:
- Performance compliant with relevant sections of MIL-PRF-6106 for established reliability electromagnetic relays
- Environmental testing per MIL-STD-810 methods for vibration, shock, and temperature performance
- Materials compliance with RoHS environmental directives
- Manufacturing processes suitable for aerospace and defense applications
- Documentation supporting military system qualification and certification
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Customization Options
YM offers tailored solutions for specific application requirements:
- Mounting Variations: Options with or without mounting ears to match specific installation requirements
- Voltage Variants: Custom coil voltages for specific system architectures
- Contact Material Options: Special contact materials for specific load types or environmental conditions
- Enhanced Testing: Additional screening and testing protocols for critical applications
- Documentation Packages: Customized technical data packages for qualification processes
Production Process & Quality Assurance
Each P3C54 relay undergoes rigorous manufacturing and testing:
- Material Qualification: All materials sourced from qualified suppliers with full traceability documentation.
- Precision Component Manufacturing: DPDT components manufactured to exacting tolerances for reliable dual-circuit operation.
- Controlled Assembly: Assembly in cleanroom conditions ensuring proper alignment of dual contact systems.
- Hermetic Sealing: Advanced sealing techniques providing environmental protection for both internal circuits.
- Comprehensive Electrical Testing: 100% testing of both poles for contact resistance, timing, and insulation characteristics.
- Final Quality Verification: Complete inspection and performance validation before release.
DPDT Advantage for Military Applications
The DPDT configuration provides specific benefits for military systems:
- vs. Multiple SPST Relays: Reduced component count, simplified wiring, and synchronized switching.
- vs. PCB Signal Relay Arrays: Superior environmental protection and power handling capability.
- vs. Solid State Relay Solutions: True galvanic isolation on both circuits and inherent surge tolerance.
- vs. Standard Automotive Relay: Military-grade environmental protection and reliability standards.
- Circuit Design Flexibility: Enables pole reversal, dual load control, and complex switching patterns in single component.
Frequently Asked Questions (FAQ)
Q1: What are the advantages of the "without ear" mounting version?
A: The "without ear" version provides a more compact footprint for space-constrained PCB designs, reduces weight, and allows for more flexible mounting arrangements. It's particularly useful in densely packed avionics and drone electronics where every millimeter counts.
Q2: Can both poles of the DPDT relay be used simultaneously at full rated current?
A: Yes, both poles are rated for simultaneous operation at the full 1A, 28V DC load. However, thermal considerations should be evaluated when both poles operate continuously at maximum ratings in high ambient temperatures.
Q3: How does the P3C54 compare to using two separate SPST relays?
A: The P3C54 offers synchronized switching, reduced component count, simplified wiring, and guaranteed timing alignment between poles. It also provides space savings and potentially higher reliability through reduced interconnection points.
Q4: Is this relay suitable for switching both AC and DC loads?
A: While primarily designed and rated for DC loads as specified, the contacts may handle similar AC ratings. For AC applications, verify dielectric strength and arc interruption characteristics for your specific AC voltage and load type.
Q5: What support is available for designing with DPDT functionality?
A: Our technical team provides application support including circuit design recommendations, PCB layout guidelines, and switching pattern optimization for maximizing the benefits of DPDT configuration.
Q6: Can customized versions with different pin configurations be provided?
A: Yes, as an experienced OEM/ODM manufacturer, we can develop variants with customized pin configurations, contact arrangements, or special features for qualified military and aerospace programs.
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