Users should thoroughly review the technical data before selecting a product part number.
It is recommended that users also seek out the pertinent approvals files of the
agencies/laboratories and review them to ensure the product meets the requirements for
a given application.
General Information
The mercury-wetted contact relay represents one of the more sophisticated types of relays
made today. The early pioneer work in mercury-wetted contact switching dates back to the
1950’s, as telephone laboratory scientists sought out the “perfect contact”. Mercury-
wetted contacts represent the nearest thing to the perfect contact yet developed, being
characterized by such parameters as: bounce-free operation; very low and stable contact
resistance; hermetic protection; fast operating speeds; Form C or Form D contact, action
contact life measured in billions of operations. The only major weakness of a mercury-
wetted contact relay is the necessity to mount the relay within 30° of a vertical position, due
to its position sensitivity.
While there are several variations of the mercury-wetted contact relay on the market, the
basic contact element has essential concepts in common. The mercury-wetted contact
element consists of a glass-encapsulated nickel-iron reed with its base immersed in a pool
of mercury. The free reed cantilever projects upward between sets of stationary contact
electrodes, which have been glass-sealed in proper juxtaposition at the top of the glass
chamber. The mercury is induced to flow up the cantilever by capillary action, wetting
mercury on both the cantilever contact tip as well as the stationary contacts. Thus a
mercury-to-mercury contact is maintained on both the normally-closed and normally-open
contacts, and the system is self-replenishing. The 2-ampere mercury-wetted capsule is
shown far left.
Along with the inherent fast actuation of the capsule and excellent load-handling capacity,
the mercury-wetted contacts exhibit extremely long life, as the mercury films re-establish at
each closure and contact erosion is eliminated. Contact interface resistance is very low and
stable, and as the mercury films are elastic, contact bounce is eliminated. A dynamic
sequence of the mercury-wetted contact action is shown below.
While the below sequence portrays a Form D (make-before-break) contact action, a true
Form C (break-before-make) contact can be provided by proper control of the mercury film
dynamics and the contact electrode spacing.
The mercury-wetted contact capsules generally are mounted within a coil assembly, and
with appropriately mounted bias magnets, mounting base and magnetic shielded
enclosures. The more popular assemblies contain one or two capsules in a convenient
printed circuit mounting module.
Mercury-wetted relays can be adjusted to operate with very low levels of input power, in the
order of 10-20 milliwatts. Thus, power gain switching of as great as 10,000 can be
realized. For all but very light contact loads, contact protection is required to limit the current
or voltage rise time across the contacts.
2 Ampere
Capsule
Form D Mercury-Wetted Contact Action As Seen In High-Speed Sequence
(1) Mercury (shown in black) covers armature and contact points; (2) and (3) as armature moves from open to closed position, mercury filament joins both contacts momentarily;
(4) ruptured mercury surfaces accelerate away from each other, providing rapid breaking action; (5) as contact surfaces join, mercury wetting dampens rebound, eliminates
electrical chatter, and provides contact reliability.
SPDT (Form C or Form D) Contact Specifications
Material
Mercury-wetted
platinum contacts
hermetically
sealed in an
inert atmosphere
Rating (Switched Load)
2 amperes
maximum
500 volts maximum
100 VA maximum
(Carry Load)
5 amperes
maximum
Not switched
Bridging and Transfer Time
When operated by a single
DC pulse, the bridging or
transfer time will be greater
than 50 microseconds, but
less than 500 microseconds.
Specifications and availability
subject to change.
Contact Resistance
14 milliohms typical;
20 milliohms maximum
Stable within
±2 milliohms
throughout life.
Life Expectancy
1 billion
operations
minimum
at rated load
308
reference purposes only.
Dimensions are shown for
Dimensions are in inches over
(millimeters) unless otherwise
specified.
www.tycoelectronics.com
Technical support:
Refer to inside back cover.
Catalog 1308242
Issued 3-03
P&B
Mercury-Wetted Relays Contact Protection
The essentially infinite life of mercury-wetted contact relays may only be realized if the requirements for suitable contact protection are observed.
In that the goal is control of the rate of rise of voltage across the contacts when the circuit is opened (rather than peak transient limiting), the only suitable protection recognized is an RC network.
Values of R and C may be calculated using the formula shown, or may be obtained from the direct reading nomograph.
Nomograph Explanation
I=Steady state current at time of circuit opening
E=Open circuit voltage
Find I on the ordinate scale. Read C on the scale adjacent to I. R is
found at the intersection of I and E.
To reduce voltage transient amplitudes, C may
be increased up to 10 times calculated values.
(R must be calculated value.)
For I=0.5 amps or less
and
E=50 volts or less
R may be omitted
C must be calculated value
Resistor Tolerances
E
Less than 70V
70V to 100V
100V to 150V
Greater than 150V
R
R up to 2R
±50%
±10%
±5%
Specifications
Parameter
Coils
Single Wound–max. ohms
Double Wound–max. ohms
Rating–Watts Continous
Temp. Rise–°C per watt
Dielectric Breakdown–RMS,
60Hz
Insulation Resistance–Megohms–500
VDC
Capacitance–Armature
to Coi pf, Typical
Electrostatic Shielding–Optional
Typical Operate Times–mS,
2X Must Operate
Typical Release Times–mS,
2X
Contact Form Available
Adjustments Available
Single-side-stable
Bi-stable
Polar 1% Balance
Temperature Range
Weight–ounces
Encapsulant
Mounting Method
Dimensions are shown for
reference purposes only.
Dimensions are in inches over
(millimeters) unless otherwise
specified.
159 Series
8,600
4,275
2.0
30°
1,000
1,000
9.0
yes
1-3
2.5
Form C, D
yes
yes
yes
Operating °C
Storage °C
2.0
Polyurethane
PCB
Specifications and availability
subject to change.
160 Series
9,000
4,500
1.75
35°
1,000
1,000
9.0
yes
1-3
2.5
Form C, D
yes
yes
yes
All types – 38.8°C to + 85°C
All types – 65°C to + 100°C
0.5
Polyurethane
PCB
www.tycoelectronics.com
Technical support:
309
Refer to inside back cover.
Catalog 1308242
Issued 3-03
P&B
159
series
Mercury-Wetted
Reed Relays
Features
159 series relays are available in a Form C or Form D 2 amp contact arrangement,
single or dual coil and printed circuit board terminals.
Weight: 1.0 ounce
Positive potential applied to the start of the winding indicated by the symbol
will
close the contacts shown open on the electrical schematics. For reset of bistable relays,
reversed polarity must be applied.
Outline Dimensions
Wiring Diagrams
Single Coil
Double Coil
Note:
Relay must be mounted within 30° of vertical and suitable contact
protection must be used.
Part Numbering System
Relay Series
160
Enclosure And Terminals
1–.625 Ht., .125 Lg.
2–.625 Ht., .156 Lg.
3–.625 Ht., .187 Lg.
4–.625 Ht., .250 Lg.
Contacts And Adjustment
1–1D Single-Side-Stable
2–1D Bistable
5–1C Single-Side-Stable
6–1C Bistable
7–1C Dynamic (1%)
Balanced Bistable
0–Special
Coils
1A-1Z–Single Coil
2K-2V–Double Coil
7A-7T–Single Coil
8A-8Z–Bifilar Coil
9A-9Z–Double Coil
(Concentric)
1S and 2S–Special
Standard Or Special
00–Standard
A1-Z9–Special
Customer Requirement
0–Special
Example: 159-151N00 is a 159 series relay, enclosure height of .625 in., pin length of .125 in., Form C contact, single-side-stable adjustment, single coil 1N, of completely
standard construction.
Coil Characteristics and Part Numbers
One Winding Single-Side-Stable 40 Milliwatts
Coils
1A
1B
1C
1D
1E
1F
1G
1H
1J
1K
1L
1M
1N
1P
1Q
1R
1T
1U
1V
Coil Resistance
(Ohms)
2.2
3.9
6.4
9.0
14
24
34
56
86
140
225
385
620
940
1,450
2,430
3,620
5,500
8,600
Must Operate
Current (MA-DC)
116
86
67
60
47
35
32
24
20
15
12
9.0
7.0
5.8
4.8
3.6
2.9
2.5
2.0
Must Operate
Voltage (VDC)
.28
.37
.47
.60
.72
.93
1.2
1.5
1.9
2.3
2.9
3.8
4.8
6.0
7.7
9.7
12
15
19
Dimensions are in inches over
(millimeters) unless otherwise
specified.
Must Release
Voltage (VDC)
.06
.07
.09
.12
.15
.19
.24
.30
.39
.46
.59
.73
.95
1.2
1.6
2.0
2.3
3.0
3.8
Maximum
Voltage (VDC)
2.1
2.8
3.6
4.3
5.3
6.9
8.2
11
13
17
21
28
35
43
54
70
85
105
130
Specifications and availability
subject to change.
Part Number
Form C
159-151A00
159-151B00
159-151C00
159-151D00
159-151E00
159-151F00
159-151G00
159-151H00
159-151J00
159-151K00
159-151L00
159-151M00
159-151N00
159-151P00
159-151Q00
159-151R00
159-151T00
159-151U00
159-151V00
Form D
159-111A00
159-111B00
159-111C00
159-111D00
159-111E00
159-111F00
159-111G00
159-111H00
159-111J00
159-111K00
159-111L00
159-111M00
159-111N00
159-111P00
159-111Q00
159-111R00
159-111T00
159-111U00
159-111V00
www.tycoelectronics.com
Technical support:
Refer to inside back cover.
310
reference purposes only.
Dimensions are shown for
Catalog 1308242
Issued 3-03
P&B
159 Series (continued) – Coil Characteristics and Part Numbers
Two Windings Single-Side-Stable 80 Milliwatts Per Winding
Coil Resistance
(Ohms)
70/70
115/115
190/190
325/325
490/490
730/730
1250/1250
1860/1860
2760/2760
4275/4275
Must Operate
Current (MA-DC)
(Either Winding)
30
23
18
14
12
9.6
7.2
5.8
5.0
3.9
Must Operate
Voltage (VDC)
(Either Winding)
2.3
3.0
3.8
5.0
6.2
7.7
10
12
15
18
Must Release
Voltage (VDC)
(Either Winding)
.47
.60
.79
1.0
1.3
1.6
2.0
2.5
3.0
3.8
Maximum
Voltage (VDC)
(Either Winding)
12
15
19
26
31
38
50
61
74
92
Dielectric Stand
Off Between
Coils (VDC)
500
500
400
400
400
400
400
200
200
200
Part Number
Form C
159-152K00
159-152L00
159-152M00
159-152N00
159-152P00
159-152Q00
159-152R00
159-152T00
159-152U00
159-152V00
Form D
159-112K00
159-112L00
159-112M00
159-112N00
159-112P00
159-112Q00
159-112R00
159-112T00
159-112U00
159-112V00
Coils
2K
2L
2M
2N
2P
2Q
2R
2T
2U
2V
Two Windings Single-Side-Stable 40 Milliwatts Per Winding
2K
2L
2M
2N
2P
2Q
2R
2T
2U
2V
70/70
115/115
190/190
325/325
490/490
730/730
1250/1250
1860/1860
2760/2760
4275/4275
15
12
9.0
7.0
5.8
4.8
3.6
3.0
2.5
2.0
.30
.37
.47
.62
.77
.97
1.2
1.5
1.8
2.3
1.2
1.5
1.9
2.5
3.1
3.9
5.0
6.0
7.5
9.2
12
15
19
26
31
38
50
61
74
92
500
500
400
400
400
400
400
200
200
200
159-162K00
159-162L00
159-162M00
159-162N00
159-162P00
159-162Q00
159-162R00
159-162T00
159-162U00
159-162V00
159-122K00
159-122L00
159-122M00
159-122N00
159-122P00
159-122Q00
159-122R00
159-122T00
159-122U00
159-122V00
Two Windings Bifilar Windings Bistable 40 Milliwatts Per Winding
8A
8B
8C
8D
8E
8F
8G
8H
8J
8K
135/135
170/170
200/200
310/310
460/460
675/675
810/810
1000/1000
1240/1240
2300/2300
16
15.5
13.3
11.9
7.8
6.5
6.85
6.75
5.6
3.82
.48
.58
.58
.82
.80
.96
1.2
1.5
1.4
1.9
2.4
2.9
2.9
4.1
4.0
4.8
6.1
7.4
7.0
9.7
16.4
18.5
20.0
24.9
30.3
36.7
40.2
44.7
49.8
67.8
500
400
400
400
400
400
400
400
400
200
159-168A00
159-168B00
159-168C00
159-168D00
159-168E00
159-168F00
159-168G00
159-168H00
159-168J00
159-168K00
159-128A00
159-128B00
159-128C00
159-128D00
159-128E00
159-128F00
159-128G00
159-128H00
159-128J00
159-128K00
Note:
All values at 25°C. Resistances specified are ±10%. Maximum voltages based on 2 watts continuous dissipation.
One Winding Single-Side-Stable 115 Milliwatts And Bistable 25 Milliwatts
Single-Side-Stable
Nominal
Must Operate Must Operate
Resistance
Voltage
Current
(Ohms)
(VDC)
(MA-DC)
18
65
85
90
115
275
450
675
940
950
1250
1425
1800
1950
2400
4000
4000
66.6
37.4
33.3
37.7
30.0
17.0
12.9
11.6
10.1
12.1
9.4
8.3
9.4
7.5
7.35
5.55
1.3
2.7
3.1
3.8
3.8
5.2
6.4
8.6
10.5
12.7
12.9
13
18.6
17.6
20.6
24.4
17.6
Must
Release
Voltage
(VDC)
.18
.36
.42
.51
.51
.77
.85
1.1
1.4
1.7
1.8
1.8
2.6
2.1
2.6
3.3
2.4
Maximum
Voltage
(VDC)
6.0
11.4
13.0
13.4
15.1
23.4
30.0
36.7
43.3
43.6
50.0
53.4
60.0
62.4
69.2
89.5
89.5
Part Number
Form C
159-157A00
159-157B00
159-157C00
159-157D00
159-157E00
159-157F00
159-157G00
159-157H00
159-157J00
159-157K00
159-157L00
159-157M00
159-157N00
159-157P00
159-157Q00
159-157R00
159-157T00
Form D
159-117A00
159-117B00
159-117C00
159-117D00
159-117E00
159-117F00
159-117G00
159-117H00
159-117J00
159-117K00
159-117L00
159-117M00
159-117N00
159-117P00
159-117Q00
159-117R00
159-117T00
Must Operate Must Operate
Current
Voltage
(MA-DC)
(VDC)
31.2
17.8
15.6
17.6
14.0
8.0
6.0
5.4
4.7
5.7
4.4
3.9
4.4
3.5
3.4
2.6
1.9
.12
.26
.30
.36
.36
.50
.60
.80
.98
1.2
1.2
1.2
1.7
1.5
1.8
2.3
1.6
Bistable
Must
Release
Voltage
(VDC)
.62
1.3
1.5
1.8
1.8
2.5
3.0
4.0
4.9
6.0
6.1
6.2
8.8
7.5
9.0
8.3
Part Number
Form C
159-167A00
159-167B00
159-167C00
159-167D00
159-167E00
Form D
159-127A00
159-127B00
159-127C00
159-127D00
159-127E00
159-167F00 159-127F00
159-167G00 159-127G00
159-167H00 159-127H00
159-167J00 159-127J00
159-167K00 159-127K00
159-167L00
159-167M00
159-167N00
159-167P00
159-167Q00
159-167R00
159-167T00
159-127L00
159-127M00
159-127N00
159-127P00
159-127Q00
159-127R00
159-127T00
Dimensions are shown for
reference purposes only.
Dimensions are in inches over
(millimeters) unless otherwise
specified.
Specifications and availability
subject to change.
www.tycoelectronics.com
Technical support:
311
Refer to inside back cover.
Catalog 1308242
Issued 3-03
P&B
160
series
Mercury-Wetted
Reed Relays
Features
160 series relays are available in a single Form C or Form D two ampere
contact arrangement, single or dual coil and printed circuit board
terminals.
The part numbers shown on the adjacent page are for relays with 0.093”
terminal spacing. The part number designator for the 0.100” grid is a 160-
3XXXXX for a pin of 0.09” length, and 160-4XXXXX for a pin of 0.125”
length.
Positive potential applied to the start of the winding indicated by the
symbol will close the contacts shown open on the electrical schematics.
For reset of bistable relays, reversed polarity must be applied. Weight 0.5
ounces. UL File E55708
Note:
Relay must be mounted within 30° of vertical and suitable
contact protection must be used.
Outline Dimensions
Wiring Diagrams
Grid 0.093
(160-1)
(160-2)
Grid 0.100
(160-3)
(160-4)
Single Coil
Double Coil
Part Numbering System
Relay Series
160
Enclosures And Terminals
1–.090 Lg., .093 Grid
2–.125 Lg., .093 Grid
3–.090 Lg., .100 Grid
4–.125 Lg., .100 Grid
Contacts and Adjustments
1–1D Single-Side-Stable
2–1D Bistable
5–1C Single-Side-Stable
6–1C Bistable
7–1C Dynamic (1%)
Balanced Bistable
0–Special
Coil
1A-1Z–Single Coil
2A-2Z–Double Coil
1S–Special Single Coil
2S–Special Double Coil
Standard or Special
00–Standard
A1-Z9–Special
Customer Requirement
0–Special
Example: 160-151K00 is a 160 series relay, enclosure height of .400 in., pin length of .090 in., Form C contact, single-side-stable adjustment,
single coil 1K, of completely standard construction.
Coil Characteristics and Part Numbers
Two Windings Bistable 20 Milliwatts Per Winding
Coil Resistance
(Ohms)
60/60
90/90
155/155
205/205
340/340
560/560
870/870
1320/1320
1980/1980
3000/3000
4500/4500
Must Operate
Current (MA-DC)
(Either Winding)
17
15
11
10
7.5
6.0
4.7
3.8
3.2
2.7
2.1
Must Not Operate
Voltage (VDC)
(Either Winding)
.29
.38
.49
.61
.73
.98
1.2
1.4
1.8
2.3
2.8
Must Operate
Voltage (VDC)
(Either Winding)
1.1
1.5
1.9
2.3
2.8
3.6
4.5
5.5
7.0
9.0
11.0
Maximum
Dielectric Standoff
Voltage (VDC)
Between Coils
(One Winding Only)
(VDC)
10
13
16
19
24
31
39
48
59
73
89
500
400
400
400
400
400
200
200
200
200
200
Part Number
Form C
160-162K00
160-162L00
160-162M00
160-162N00
160-162P00
160-162Q00
160-162R00
160-162T00
160-162U00
160-162V00
160-162W00
Form D
160-122K00
160-122L00
160-122M00
160-122N00
160-122P00
160-122Q00
160-122R00
160-122T00
160-122U00
160-122V00
160-122W00
Coil
2K
2L
2M
2N
2P
2Q
2R
2T
2U
2V
2W
Note:
All values at 25°C. Resistances specified are ±10%. Maximum voltages based on 1.75 watts continuous dissipation.
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