1304719 - 12 Volt Plastic Case Insulated Solenoid Intermittent Duty 150 Amp Motor Relay

The continuous duty 12 Volt Plastic Case Solenoid from Buyers Products will not overheat when you are operating your plow or spreader, keeping you out of the cold. Its low-input, high-output operation is ideal for 12V vehicle starters, cranes, lift gates, snow plows, and salt spreaders that require heavy duty electric motors. Available in a continuous motor relay and an intermittent 150A motor relay option, the waterproof, sealed design will keep your engine starting reliably all season.

Specifications

Comprehensive Technical Overview: 12 Volt Plastic Case Insulated Solenoid Intermittent Duty 150 Amp Motor Relay

This detailed technical description provides an in-depth exploration of the 12 Volt Plastic Case Insulated Solenoid Intermittent Duty 150 Amp Motor Relay, a crucial component engineered for demanding automotive and heavy-duty industrial applications. Designed to facilitate the reliable switching of high electrical currents, this solenoid serves as an indispensable interface between a low-current control signal and high-current power circuits, particularly those driving powerful electric motors. Its robust construction, specified intermittent duty cycle, and high current handling capability underscore its suitability for critical roles in harsh operating environments.

Fundamentals of Solenoid Operation and Functionality

At its core, a solenoid is an electromechanical device that converts electrical energy into mechanical energy, primarily for switching purposes. It consists of a coil of wire, an armature (or plunger), and a set of electrical contacts. When an electric current flows through the coil, it generates a magnetic field. This magnetic field attracts the armature, causing it to move and, in turn, either open or close a set of heavy-duty contacts. In the context of a motor relay, these contacts are designed to carry significant electrical loads to power a motor. The distinction between a solenoid and a standard relay often lies in its capacity to handle higher currents and the physical size and robustness of its contacts, which are engineered to withstand the arcing and wear associated with high-amperage switching. The described unit functions as a 4-post switch, typically meaning two smaller terminals for the activation coil and two larger terminals for the main power circuit, facilitating a Normally Open (NO) configuration where the main circuit is closed only when the coil is energized.

Optimized for 12 Volt Electrical Systems

The ubiquity of 12-volt direct current (DC) electrical systems in vehicular and mobile equipment makes this solenoid an ideal fit for a vast array of applications. Standardized 12V systems provide a balance between power delivery efficiency and component sizing, making them a practical choice for systems that require robust electrical power for various accessories and propulsion. This solenoid is specifically designed to operate flawlessly within these parameters, ensuring compatibility and seamless integration into existing vehicle architectures without requiring complex voltage conversion or adaptation. Its 12V coil ensures it can be driven directly by standard vehicle control signals, minimizing installation complexity and maximizing system reliability.

Understanding Intermittent Duty Cycle (150 Amp)

The designation "Intermittent Duty" is a critical specification that defines the operational characteristics and thermal management profile of this solenoid. An intermittent duty cycle implies that the device is designed to conduct its rated current (150 Amps in this case) for short, specified periods, followed by sufficient off-periods to allow for cooling. This contrasts sharply with "continuous duty" devices, which are engineered to carry their rated current indefinitely without overheating. For applications such as motor starting, momentary power delivery to hydraulic pumps, or activating electric winches, the power requirement is intense but brief. The 150 Amp rating indicates the maximum current the contacts can safely switch and carry during these brief operational cycles. Engineers design intermittent duty solenoids with specific thermal tolerances that account for rapid heat generation during activation and subsequent dissipation during rest periods. This design optimizes for cost and size by not over-engineering for continuous thermal loads that are not present in the intended use cases, ensuring efficient material usage while maintaining peak performance when required. The ability to handle 150 Amps means it can manage the high inrush currents often associated with starting DC electric motors under load.

Superior Material Construction: Plastic Case and Insulation

The choice of a "Plastic Case" constructed from a high-grade polymer offers several distinct advantages over traditional metal housings. Polymers provide inherent resistance to corrosion, a significant benefit in environments exposed to moisture, road salt, chemicals, and other corrosive agents prevalent in outdoor and automotive applications. Unlike metal, which can corrode and lead to structural degradation or electrical failures, a polymer housing ensures long-term integrity and aesthetic retention. Furthermore, the plastic case contributes to the "Insulated" characteristic of the solenoid. It provides excellent electrical insulation, safeguarding against accidental short circuits or ground faults, particularly when mounted in close proximity to other metallic components or the vehicle chassis. This insulation enhances overall system safety and prevents unintended current paths. The lightweight nature of polymer also contributes to a lower overall vehicle weight, which can be a minor but cumulative advantage in vehicle design. The robust polymer casing is also designed to withstand mechanical shock and vibration, common occurrences in mobile and heavy-duty equipment, thereby contributing to the solenoid's extended operational lifespan.

Engineered for Environmental Resilience: Waterproof and Sealed Design

The "Waterproof, Sealed Design" is a paramount feature for a component destined for outdoor and vehicle-mounted applications. This design ensures that the internal electromechanical components, specifically the coil and contact assembly, are protected from ingress by moisture, dust, dirt, and other particulate matter. While an explicit Ingress Protection (IP) rating is not provided, the description implies a high level of environmental sealing, crucial for reliable operation in challenging conditions like those encountered by snow plows, salt spreaders, and construction equipment. Protection against water prevents short circuits, corrosion of electrical contacts, and degradation of the coil winding insulation, all of which can lead to premature failure. Dust and debris exclusion prevents mechanical interference with the armature's movement and abrasive wear on contact surfaces. This sealed construction significantly extends the operational lifespan of the solenoid, reduces maintenance requirements, and ensures consistent performance regardless of weather conditions or exposure to harsh operational environments.

Key Applications and Performance Advantages

This 12 Volt Intermittent Duty 150 Amp Solenoid is specifically engineered to excel in applications demanding high-current switching for short durations. Its "low-input, high-output operation" efficiently translates a relatively small control current into the capability to manage substantial power loads, making it indispensable for:

• Vehicle Starters: Modern internal combustion engines, especially in heavy-duty vehicles, require a significant surge of current to crank the engine. The solenoid acts as the critical switch, connecting the battery directly to the starter motor for the brief period of engine cranking. Its 150 Amp intermittent rating is perfectly suited for handling the high inrush current and subsequent load of a starter motor.
• Cranes and Lift Gates: Hydraulic power units driving cranes and lift gates often employ electric motors that operate intermittently. Whether raising or lowering a load, these motors demand high current for the duration of the operation cycle. The solenoid provides reliable, on-demand power switching, ensuring precise control and robust power delivery for heavy lifting tasks.
• Snow Plows and Salt Spreaders: These applications operate in some of the most challenging conditions imaginable—extreme cold, moisture, corrosive salt, and heavy vibrations. The motors driving hydraulic pumps for plow articulation and spinner mechanisms for spreaders require intermittent bursts of high current. The solenoid's waterproof, sealed, and corrosion-resistant polymer housing, coupled with its intermittent duty rating, ensures dependable operation through harsh winter seasons, keeping equipment running when it's needed most.
• Other Heavy Duty Electric Motors: Beyond these specific examples, any application utilizing heavy-duty 12V DC electric motors that operate intermittently—such as winches, auxiliary pumps, or specialized agricultural equipment—will benefit from the robust and reliable current switching provided by this solenoid.

Detailed Analysis of Technical Specifications

The provided specifications offer precise insights into the solenoid's design, dimensions, and functional characteristics:

• Compares To: Boss HYD01633: This comparison indicates direct interchangeability or functional equivalence with a well-established component in the industry. For users, this means assured compatibility with systems designed to accept the Boss HYD01633, simplifying replacement and integration processes. It also suggests adherence to recognized industry standards for form, fit, and function, providing confidence in its performance and reliability.
• Current Rating: 150 Amps: As previously detailed, this is the maximum current that the solenoid's main contacts are designed to safely switch and carry during its intermittent operational cycles. This high rating is indicative of its suitability for substantial electrical loads, protecting downstream components from excessive current spikes and ensuring efficient power transfer.
• Depth: 2.625 inches (66.675 mm) | Height: 2.50 inches (63.5 mm) | Width: 2.75 inches (69.85 mm): These precise dimensions are critical for installation planning and ensuring adequate clearance within confined spaces. The compact footprint allows for versatile mounting options, even in equipment bays where space is at a premium. Accurate dimensional data prevents installation complications and facilitates seamless integration into existing assemblies.
• Duty: Intermittent: Reaffirming its design for short, high-power bursts followed by rest periods. This is a fundamental characteristic dictating its application scope and thermal management profile.
• Housing Material: Polymer: Emphasizes the use of advanced plastic composites, providing benefits such as corrosion resistance, electrical insulation, reduced weight, and enhanced durability against physical impacts and environmental stressors.
• Mount Style: Right Angle Bracket: The inclusion of a right-angle mounting bracket offers a straightforward and secure installation method. This style typically involves mounting the solenoid directly to a flat surface, with the terminals facing outwards, simplifying wiring access and minimizing the risk of strain on electrical connections. The fixed bracket ensures stable placement, even under significant vibration.
• Mounting Hardware Included (y/n): n: This specification clarifies that mounting hardware (e.g., screws, bolts, nuts) is not included with the unit. Users should be prepared to source appropriate hardware for their specific installation, allowing for customization based on mounting surface material and thickness.
• Number of Terminals: 4 | Switch Style: 4 Post: This configuration is standard for many automotive and heavy-duty solenoids. Typically, two smaller posts are for the control circuit (coil activation, positive and negative/ground), and two larger posts are for the high-current power circuit (input from battery, output to motor). This 4-post design simplifies wiring and ensures clear separation between control and power lines, enhancing safety and troubleshooting efficiency. The large posts are designed to handle the 150A current, requiring robust cable connections.

Engineering Principles and Robust Design

The design of this intermittent duty solenoid incorporates several sophisticated engineering principles to ensure its reliability and longevity:

• Contact Material and Arc Suppression: The internal contacts are typically crafted from silver alloy composites, chosen for their excellent electrical conductivity, high resistance to welding under load, and superior arc quenching capabilities. During high-current switching, electrical arcs are inevitable. The material composition and geometry of the contacts, combined with the sealed environment, are optimized to minimize arc erosion and extend contact life.
• Coil Design and Efficiency: The electromagnetic coil is precisely wound to draw a minimal control current while generating a robust magnetic field sufficient to actuate the armature reliably. The coil's resistance and insulation are designed to withstand thermal cycling and continuous control voltage application during its active phase without degradation.
• Mechanical Integrity: Components such as the return spring, armature, and pivot points are designed for millions of cycles. Materials are selected for their fatigue resistance and ability to maintain consistent performance under varied operating temperatures and vibration profiles. The internal mechanical structure is designed to absorb shock and maintain alignment, ensuring smooth and consistent operation over time.
• Thermal Management: Although intermittent duty, effective thermal management is still paramount. The polymer housing, while an insulator, is designed in conjunction with internal components to allow for efficient heat dissipation during off-cycles, preventing cumulative heat buildup that could lead to premature failure.
• Voltage Drop Minimization: The design prioritizes minimal voltage drop across the main power contacts when energized. Low resistance contacts are crucial to ensure that maximum power is delivered to the motor, preventing energy loss as heat and ensuring the motor receives its optimal operating voltage for peak performance.

Installation and Maintenance Guidelines

While the product is designed for robust performance, proper installation is key to realizing its full potential. Ensure that electrical connections to the 4 terminals are secure, clean, and properly sized for the 150 Amp current rating (for the main power terminals) and the control current (for the coil terminals). Loose connections can lead to resistance, heat buildup, and potential failure. The right-angle mounting bracket facilitates a secure mechanical attachment to a stable surface, mitigating the effects of vibration. Due to its sealed design and corrosion-resistant housing, the solenoid generally requires minimal maintenance once installed correctly. Periodic inspection of connections for corrosion or loosening is advisable, especially in highly exposed or vibrating applications.

Conclusion

The 12 Volt Plastic Case Insulated Solenoid Intermittent Duty 150 Amp Motor Relay stands as a testament to precision engineering for demanding applications. Its careful balance of high current capability, intermittent operational profile, environmental resilience, and robust polymer construction makes it an indispensable component for critical vehicular and industrial systems. From ensuring reliable engine starts to powering heavy-duty auxiliary equipment in the most challenging conditions, this solenoid delivers consistent, high-performance switching, embodying durability, safety, and efficiency. Its design reflects a deep understanding of the practical requirements for heavy-duty electrical components, providing a dependable solution for professionals seeking uncompromising reliability in their equipment.