These are Phoenix relays with cracks, and they operate on a 150-millisecond operating system. Is there an explanation for these cracks?
• Check the load voltage, it must fit the relay
• Cracks could happen due to heat
• Maybe the relay is not well dimensioned to the load and the frequency of the use. There are temporary solutions like putting another bigger relay under or more permanent changing the relay to a bigger one or combining it with a contactor depending on the load.
• It could also be because of overheating so check the ventilation and operational temperature.
The mentioned parameters like the 150 milliseconds operating time can make Phoenix relays develop cracks for several reasons, described in the current work. As to one of the main assumptions of the present article one can identify thermal stress as the source of cracks. When relays work in high frequencies that require small intervals between the poles and/or when relays operate in high current, they heat and the internal components or the casing expand and contract. Such thermal cycling over time, causes the relay housing or internal components to crack and that is why it commonly fails.
The mechanical stress resultant from vibrations or wrong installation into the system could also be another cause as this acts to exert exigent physical pressure on the relay body. This is particularly important in high speed applications where relays may be switched on and off frequently or where there are large inrush currents which normally cause increased fatigue of the contacts. Further, the cracks may also result from material fatigue or manufacturing imperfection of the relays, particularly where the relays are used under severe conditions of service such as high temperatures or high voltage surge. Some of these problems include and normal checking and making sure that the relay is functioning as supposed must be conducted so that they do not arise.