PL-5 Aviation Coil Latching Relay – 1A 5V / 12V for Signal Control in Aircraft & Aerospace
Product Overview
The PL-5 series is a high-reliability Aviation Latching Relay (single-coil bistable) designed for flight-critical signal switching applications. Rated at 1A 30VDC and available in 5V or 12V coil versions, the PL-5 consumes only 0.3~0.43W during pulse operation and retains its contact state without continuous coil power – essential for power-constrained avionics. This Latching Relay features hermetically sealed construction (≤10⁻³ Pa·cm³/s), fast switching (≤4ms), and excellent low-level signal capability (10~50μA). As part of YM’s aerospace-grade relay family – which includes Metal Sealing Relay, Polarized Relay, Military Metal Relay, PCB Signal Relay, and Aviation Microswitch – the PL-5 meets stringent MIL-PRF-39016 and DO-160 environmental standards, making it ideal for aircraft flight controls, navigation systems, and ground support equipment.
Technical Specifications
Coil Parameters (Single-Coil Latching, Polarity Sensitive)
- Coil power consumption (pulse): (0.3~0.43)W
- Nominal coil voltages: 5V DC or 12V DC (specify when ordering)
- Incentive pulse width: (10～50) ms – sufficient to switch state
- Coil resistance (5V version): Approx. 58~83Ω; (12V version): Approx. 335~480Ω at 25°C
Contact Ratings
- Maximum switching current: 1A at 30V DC (resistive load)
- Reference resistive load: 1A, 28V DC, 1×10⁵ operations
- Low level switching capability: (10~50)μA, (10~50)mV – 1×10⁵ operations, ideal for dry circuit (e.g., sensor signals)
- Initial contact resistance: ≤50mΩ; after life test ≤200mΩ
Timing & Dielectric
- Action time (operate): ≤4ms (typical ≤3ms)
- Release time (reset): ≤4ms
- Dielectric strength (normal atmosphere): 500Vr.m.s., 50Hz; under low pressure (15,000 ft equivalent): 250Vr.m.s., 50Hz
- Insulation resistance (normal atmosphere): >500MΩ; after high-level life test: >50MΩ
Mechanical & Environmental (Aviation Grade)
- Weight: <3g – ultra-light for airborne equipment
- Sealing (leakage rate): ≤10⁻³ Pa·cm³/s (hermetic, glass-to-metal seal)
- Operating temperature range: -65°C to +125°C (extended aviation range)
- Shock & vibration: Withstands 50g, 6ms half-sine; 10-2000Hz, 20g random vibration per RTCA/DO-160
- Terminal style: Standard DIP or solder hook (aviation preferred)
All parameters are validated at 25°C ambient. The PL-5 is manufactured and tested to MIL-PRF-39016 requirements for hermetically sealed relays.
Product Images & Visuals
Above: PL-5 series latching relay in hermetically sealed package. Contact YM for outline dimensions, mounting recommendations, and environmental qualification reports.
- True latching (bistable) with single coil: Polarity-sensitive design – positive pulse sets, negative pulse resets. Zero holding power eliminates coil heating and reduces power supply load – critical for battery-backed avionics and emergency systems.
- Ultra-low coil power (0.3~0.43W): Allows direct drive from low-power logic (e.g., 5V TTL/CMOS) with simple H-bridge or dual MOSFET driver – reduces component count and PCB area.
- Hermetic sealing (≤10⁻³ Pa·cm³/s): Glass-to-metal seal protects contacts from humidity, salt spray, and altitude pressure changes – ensures reliable operation in unpressurized aircraft compartments and ground radar shelters.
- Wide temperature & vibration tolerance: -65°C to +125°C operation and 20g vibration meet RTCA/DO-160 Section 8 (vibration) and Section 4 (temperature/altitude).
- Excellent low-level signal switching: Gold-plated contacts reliably switch down to 10μA / 10mV – perfect for flight data acquisition, sensor multiplexing, and discrete inputs.
- Fast switching (≤4ms) & high isolation: 500Vrms dielectric strength and >500MΩ insulation resistance prevent crosstalk in mixed signal environments.
YM’s aviation engineering advantage: The PL-5 leverages magnetic circuit design proven in our Military Metal Relay and Polarized Relay families, offering consistent pull-in sensitivity across temperature extremes. Compared to non-latching signal relays, the PL-5 reduces system power by >95% in steady-state conditions – a key benefit for long-endurance UAVs and satellite ground terminals. For complete cockpit signal switching, YM also provides Aviation Button Switch, Aviation Rocker Switch, Aviation Connector, and Aviation Microswitch products, ensuring a unified supply chain for aircraft OEMs.
How to Use the PL-5 Single-Coil Latching Relay – Step by Step
- Identify coil polarity: The PL-5 is a single-coil latching relay. Pin assignment: coil+ (set) and coil- (reset). Applying a positive voltage (e.g., +5V or +12V) to coil+ relative to coil- will set the relay (contacts close). Reversing polarity (negative voltage on coil+) will reset the relay (contacts open).
- Generate bipolar pulse: Use an H-bridge driver (e.g., two N-channel + two P-channel MOSFETs) or a dual relay driver with polarity reversal. The pulse width should be 10-50 ms – longer pulses may overheat the coil.
- Set the relay: Apply a positive pulse (Vnominal) to the coil for 20ms typical. The relay will latch into the set state. Remove the pulse – the contacts remain closed indefinitely without any coil current.
- Reset the relay: To open the contacts, apply a negative pulse (reverse polarity) of the same voltage and duration. After the pulse, the relay latches into the reset state (contacts open).
- Connect load: The PL-5 is optimized for signal-level loads (1A max at 30VDC). For avionics discrete signals (e.g., 28V/0.5A lamp or relay coil), the contacts will perform reliably. For dry circuits (μA/mV), no special cleaning is needed due to gold plating.
- PCB mounting: The PL-5 is available in through-hole DIP or solder-hook terminals for wire wrapping. Follow IPC-A-610 for soldering (maximum 260°C for 5 seconds). Avoid flux residue that could compromise hermeticity – use no-clean flux.
Pro tip for avionics engineers: To ensure fail-safe behavior, design the H-bridge with pull-down resistors so that coil pins are not floating during power-up. The PL-5’s latching state is indeterminate after initial power-on – always execute a known set or reset sequence during system initialization.
Application Scenarios & Key Buyer Benefits
Typical Aviation & Aerospace Uses
- Flight control systems (autopilot, trim actuators): Latching relays hold control line configuration without continuous power – reduces heat in tightly packed LRUs (line replaceable units).
- Navigation & communication equipment: VOR/ILS frequency switching, transponder mode selection – low-level signal capability ensures no distortion of sensitive RF/analog paths.
- Mission computers & data recorders: Relay multiplexing for discrete I/O expansion – saves GPIO pins while maintaining state during power cycles.
- Ground support equipment (test stands, radar): Hermetic sealing protects against desert dust and humidity – reduces field maintenance.
- Unmanned aerial vehicles (UAVs) & drones: Lightweight (<3g) and low power consumption extend flight time and allow dense PCB stacking.
Direct Value to International Buyers (OEMs, MROs, Distributors)
- Reduced system power & thermal load: Zero holding power means no derating for temperature – allows higher packing density in avionics bays.
- Lower cost of ownership: Hermetic sealing eliminates contact oxidation failures, reducing unscheduled maintenance and improving dispatch reliability.
- Simplified power supply design: Pulse operation eliminates need for continuous coil drivers and heat sinks – lowers BOM cost by up to 30% compared to non-latching relays with similar ratings.
- Global regulatory compliance: RoHS/REACH compliant, with qualification data to MIL-PRF-39016 and RTCA/DO-160 – smooth acceptance by civil and defense aviation authorities.
- Supply chain consolidation: The PL-5 complements YM’s full suite of aviation components: Military Aviation Encoding Switch, Aviation Magnetic Valve, Aviation Oil Sealed Valve, Aviation Hours Timer, and Military Pressure Sensor – one qualified source for multiple subsystems.
For aftermarket MRO providers, the PL-5 offers a form-fit-function replacement for obsolete latching relays used in legacy aircraft (e.g., C-130, Black Hawk, Boeing 737 classic). YM can provide cross-reference guides and sustainment support.
Certifications & Compliance
- MIL-PRF-39016 (hermetic, signal relay) – qualification data available upon request.
- RTCA/DO-160G (environmental conditions for airborne equipment): tested for temperature/altitude (Cat. A2), vibration (Cat. S), humidity, and salt spray.
- 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, set/reset voltage, contact resistance, dielectric strength, and insulation resistance. Sample relays from each lot undergo destructive physical analysis (DPA) per MIL-STD-1580. YM can provide Certificate of Conformance (CoC) and test data for every shipment.
Customization Options
YM supports tailored PL-5 variants for specific aircraft platforms and special applications. For volume orders, the following modifications are available:
- Coil voltage: 3V, 6V, 9V, 15V, 24V, 28V DC (customized to match avionics bus).
- Contact material: Gold overlay (standard for low-level), AgPd (for mixed load), or Rhodium (for ultra-low level, <1μA).
- Terminal style & finish: Solder hook, straight DIP, or surface-mount gull-wing; tin or gold plating.
- Sealing enhancement: Additional epoxy coating for extreme chemical resistance (e.g., fuel vapors).
- Marking & traceability: Laser engraving of customer part number, batch traceability code, or special inspection stamps (e.g., “SJ” for space qualified).
- Screening level: Commercial (standard), high-reliability (100% burn-in, temperature cycling), or space-level (DPA, radiation testing).
Our engineering team provides application support, including SPICE models, thermal derating curves, and driver circuit recommendations. Minimum order quantities for custom variants apply – contact YM with your requirements.
Production Process & Quality Assurance (AS9100D Certified)
YM’s Aviation Relay production line follows a zero-defect, fully traceable process designed to meet AS9100D and customer-specific requirements (e.g., Boeing D6-xxxx, Airbus APxxxx).
- Incoming material control: 100% verification of magnetic alloys, contact wires, glass preforms, and ceramic headers – 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 set/reset voltage, operate/release time, contact bounce, dynamic contact resistance, 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.
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