INCH-POUND MIL-PRF-39016/10G 8 November 2004 SUPERSEDING MIL-PRF-39016/10F 20 July 1988 PERFORMANCE SPECIFICATION SHEET RELAYS, ELECTROMAGNETIC, ESTABLISHED RELIABILITY, SPDT, LOW LEVEL TO 1.0 AMPERE (SENSITIVE, 40 MILLIWATTS, COIL OPERATE POWER AT 25C) This specification sheet is approved for use by all Departments and Agencies of the Department of Defense. The complete requirements for acquiring the relays described herein shall consist of this specification sheet and the latest issue of MIL-PRF-39016. Inches .001 .002 .003 .017 .031 .035 .200 .275 .335 .370 .375 mm 0.03 0.05 0.08 0.43 0.79 0.89 5.08 6.99 8.51 9.40 9.53 NOTES: 1. Dimensions are in inches. 2. Metric equivalents are given for general information only. 3. Unless otherwise specified, tolerance is .010 (0.25 mm). 4. Terminal numbers shown above for reference only. Numbers do not appear on relays. 5. Coil symbol optional in accordance with MIL-STD-1285. 6. Circuit diagram shown on part is the terminal view. FIGURE 1. Dimensions and configuration. AMSC N/A FSC 5945 MIL-PRF-39016/10G Inches .001 .002 .003 .012 016 .017 .031 .035 .100 .150 .200 .275 .300 .335 .370 ..493 mm 0.03 0.05 0.08 0.30 0.41 0.43 0.79 0.89 2.54 3.81 5.08 6.99 7.62 8.51 9.40 12.52 NOTES: 1. Dimensions are in inches. 2. Metric equivalents are given for general information only. 3. Unless otherwise specified, tolerance is .010 (0.25 mm). 4. Spreader mounting pads shall comply with the requirements of A-A-55485, A-55485/05-004. 5. Dimensions and tolerance shown for the bottom view of the spreader mounting pad are for the center-to-center locations of the holes in the spreader mounting pad. 6. Shape optional within the envelope dimension. 7. Coil symbol optional in accordance with MIL-STD-1285. 8. Terminal numbers shown above for reference only. Numbers do not appear on relay. 9. Circuit diagram shown on part is the terminal view. FIGURE 2. Dimensions and configuration relay with spreader mounting pad attached. 2 MIL-PRF-39016/10G REQUIREMENTS: CONTACT DATA: Load ratings: High level (relay case grounded): Resistive: 1.0 ampere at 28 V dc. 250 milliamperes at 115 V ac 60 and 400 Hz case not grounded. 100 milliamperes at 115 V ac 60 and 400 Hz case grounded. Inductive load: 0.2 ampere at 28 V dc with 0.32 henry inductance. Lamp: 0.10 ampere at 28 V dc. Low level: 10 to 50 A at 10 to 50 mV dc or peak ac. Intermediate current: Applicable. Contact resistance or voltage drop: Initial: 0.10 ohm maximum (0.125 ohm maximum with spreader mounting pad attached). High level: During life: Not more than 5 percent of open circuit voltage. After life: 0.20 ohm maximum (0.225 ohm maximum with spreader mounting pad attached). Low level: During: 33 ohms maximum. After: 0.15 ohm maximum (0.175 ohm maximum with spreader mounting pad attached). Intermediate current: During: 1 ohm maximum. After: 0.20 ohm maximum (0.225 ohm maximum with spreader mounting pad attached). Contact bounce: 1.5 milliseconds maximum (applicable to failure rate level "L"). Contact stabilization time: 2.0 milliseconds maximum (applicable to failure rate levels "M", "P", and "R"). Overload (high level only): Two times rated current. Not applicable to ac load ratings. 3 MIL-PRF-39016/10G COIL DATA: See table I. Operate time: 4.0 ms maximum over temperature range with rated coil voltage. Release time: 2.5 ms maximum over temperature range from rated coil voltage. ELECTRICAL DATA: Insulation resistance: 10,000 megohms minimum at 500 V dc, except the resistance between coil and case at high temperature shall be 1,000 megohms minimum. Dielectric withstanding voltage: Sea level V rms (60 Hz) Between case, frame, or enclosure and all contacts in the energized and de-energized positions. Between case, frame, or enclosure and coils. Between all contacts and coils. Between open contacts in the energized and deenergized positions. Between contact poles. Between coils of dual coil relays. Post intermediate current life test Sea level V rms (60 Hz) 500 500 500 500 500 500 500 N/A N/A 375 N/A N/A Altitude V rms (60 Hz) 300 All terminals to case ENVIRONMENTAL DATA: Temperature range: -65C to +125C. Vibration (sinusoidal): MIL-STD-202, method 204. Contact chatter shall not exceed 10 microseconds maximum for closed contacts, and 1 microsecond maximum closure for open contacts. Vibration (random): MIL-STD-202, method 214, test condition IG. Contact chatter shall not exceed 10 microseconds maximum for closed contacts, and 1 microsecond maximum closure for open contacts. Applicable to qualification and group C testing only. Shock (specified pulse): MIL-STD-202, method 213, test condition B (75 g's). Contact chatter shall not exceed 10 microseconds maximum for closed contacts, and 1 microsecond maximum closure for open contacts. Magnetic interference: Applicable. Resistance to soldering heat: Applicable. Acceleration: Applicable. Salt atmosphere (corrosion): In accordance with MIL-STD-750, method 1041. 4 MIL-PRF-39016/10G PHYSICAL DATA: Terminal strength: MIL-STD-202, method 211. Pull test: Test condition A, 1 pound pull. Bend test: Test condition C, 1/2 pound load. Twist test: As specified in MIL-PRF-39016. Solderability: Applicable. Dimensions and configuration: See figures 1 and 2. Weight: 2.84 grams (0.10 ounce) maximum, 3.09 grams (0.109 ounce) maximum with spreader mounting pad attached. Seal: Hermetic. Minimum marking: Military part number, "J" with the date code (example J0430), circuit diagram, manufacturer's name or source code. LIFE TEST REQUIREMENTS: High level: 100,000 cycles per relay. Low level: 100,000 cycles plus 900,000 cycles mechanical life. Part or Identifying Number (PIN): M39016/10- (dash number from table I and suffix letter designating failure rate level). 5 MIL-PRF-39016/10G TABLE I. Dash numbers and characteristics. 1/ Dash numbers 2/ Coil voltage (V dc) 3/ Lead Lead Lead Spreader length length length mounting 1.500 .187 .500 pads Rated Max min .010 min (fig. 2) 4/ 5/ 017 019 021 023 025 027 029 031 018 020 022 024 026 028 030 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048 5.0 6.0 12.0 26.5 32 40 9.0 18 8.0 11 22 45 57 75 12 24 At 25C Coil resistance ohms 10% 125 255 1,025 4,000 6,500 11,000 630 2,300 Specified pickup value (voltage) (V dc) 2.8 3.5 7.0 14.2 18.7 23.3 5.3 10.5 Specified hold value (voltage) (V dc) 1.4 2.0 4.0 8.0 10.6 13.3 3.0 6.0 Specified dropout value (voltage) (V dc) 0.23 0.28 0.63 1.37 1.59 2.0 0.54 0.91 Over temperature range SpeciSpeci- Specified fied fied dropout pickup hold value value value (voltage) (voltage) (voltage) (V dc) (V dc) (V dc) 3.7 2.0 0.15 4.5 2.8 0.18 9.0 5.6 0.40 18 10.4 0.89 24 15 1.0 30 18.7 1.3 6.8 4.2 0.35 13.5 8.4 0.58 1/ Each relay possesses high level and low level capabilities. However, relays previously tested or used above 10 mA resistive at 6 V dc maximum or peak ac open circuits are not recommended for subsequent use in low level applications. 2/ The suffix letter L, M, P, or R, to designate the applicable failure rate level, shall be added to the applicable listed dash number. Failure rate level (percent per 10,000 cycles): L, 3.0; M, 1.0; P, 0.1; R, 0.01. Example, 017L - - - - - -018R. 3/ CAUTION: The use of any voltage less than the rated voltage will compromise the operation of the relay. 4/ 1.500 leads are inactive for new design. 5/ Relays supplied with spreader mounting pads (-041 through -048) shall have the spreader mounting pad rigidly attached. QUALIFICATION INSPECTION: Qualification inspection and sample size: See table II. TABLE II. Qualification inspection and sample size. 1/ Single submission 18 units plus 1 open unit for level L at C = 0 2/ 33 units plus 1 open unit for level M at C = 0 2/ Qualification inspection as applicable Group submission M39016/10-036 18 units plus 1 open unit for level L at C = 0 2/ 33 units plus 1 open unit for level M at C = 0 2/ Qualification inspection as applicable M39016/10-033 2 units each PIN M39016/10-034 Qualification inspection, M39016/10-035 Q1. M39016/10-037 M39016/10-038 M39016/10-039 M39016/10-040 See footnotes following page. 6 MIL-PRF-39016/10G 1/ For retention of qualification or extension of qualification to lower failure rate levels, all life test data accumulated on MIL-PRF-39016/11, /16, /21, /25, and /26 may be used in addition to MIL-PRF39016/10 data. Prior to performance of retention of qualification testing, the relay manufacturer shall preselect the sampling plan. 2/ The number of units required for qualification testing shall be increased as required in Q5, MIL-PRF39016, if the contractor elects to test the number of units permitting one or more failures. Prior to performance of qualification testing, the relay manufacturer shall preselect the sampling plan. Initial qualification of relays supplied with spreader mounting pads (-041 through -048) shall be tested as specified below: Perform the following tests as specified in the qualification inspection table of MIL-PRF-39016, in the order shown below: Before installation of spreader mounting pad: Screening, visual and mechanical examination (internal), thermal shock, resistance to solvents, vibration (sinusoidal), vibration (random), shock (specified pulse), acceleration, terminal strength, magnetic interference (when specified), capacitance (when specified), coil life (applicable to continuous duty relays only), resistance to soldering heat, salt spray (corrosion), overload (applicable to high level relays only), life, terminal strength, and intermediate current. After installation of spreader mounting pad, perform the following tests as specified in the qualification inspection table of MIL-PRF-39016, in the order shown below: Insulation resistance, dielectric withstanding voltage, static contact resistance, specified pickup, hold, or dropout values (voltages), coil resistance, operate and release time, contact dynamic characteristics, coil transient suppression (when specified), solderability, seal, visual and mechanical inspection (external). Qualification inspection (reduced testing for previously qualified relays) for relays supplied with spreader mounting pads (-041 through -048): Two units of the 26.5-volt rated coil voltage (-044) shall be tested as specified below: Before installation of spreader mounting pad, perform the following tests as specified in the qualification inspection table of MIL-PRF-39016 in the order shown below: For failure rate level L only: Screening. For failure rate levels M, P, and R: Vibration (sinusoidal) test duration shall be 10 minutes, vibration (random), and screening. After installation of spreader mounting pad, perform the following tests as specified in the qualification inspection table of MIL-PRF-39016 in the order shown below: Insulation resistance, dielectric withstanding voltage, static contact resistance, specified pickup, hold, and dropout values (voltages), coil resistance, operate and release time, contact dynamic characteristics, coil transient suppression (when specified), solderability, seal, visual and mechanical inspection (external). Group A testing for relays supplied with spreader mounting pads (-041 through -048), shall be tested as specified below: Perform seal test immediately, preceding the A2 electrical tests. Relay leads shall be formed and the spreader mounting pad removed before the seal test. After the seal test, the spreader mounting pad shall be rigidly attached to the relay and the remaining group A tests performed. 7 MIL-PRF-39016/10G Qualification inspection (reduced testing) and sample size: See table III. If the relays produced for MIL-PRF-39016/10 are similar in construction and design except for the diodes, and headers, as applicable, to the relays produced for MIL-PRF-39016/11, /16, /21, /25, or /26, then reduced testing for qualification of MIL-PRF-39016/10 relays may be performed concurrent with or subsequent to successful qualification of MIL-PRF-39016/11, /16, /21, /25, or /26. For reduced testing, see table III. TABLE III. Qualification inspection (reduced testing). Inspection 2 units each coil voltage - Q1 of qualification inspection table. 1 unsealed sample unit for internal examination. SUPERSESSION DATA: Supersession data: See table IV. TABLE IV. Supersession data. 1/ Superseded PIN M5757/69001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 New PIN M39016/102/ 019 021 023 025 027 020 022 024 026 028 017 018 029 030 031 032 Superseded PIN M39016/10001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 New part no. M39016/102/ 017 018 019 020 021 022 023 024 025 026 027 028 029 030 031 032 1/ Dash numbers -017, -019, -021, -023, -025, -027, -029, and 031 are inactive for new design and are for support of existing designs only. 2/ Complete part number shall contain suffix letter L, M, P, or R to designate failure rate level (see 2/ of table I). A part with any failure rate supersedes the applicable MIL-R-5757 part. Cross-reference for Government logistical support: See table V. 8 MIL-PRF-39016/10G TABLE V. Cross-reference for Government logistical support. Superseded PIN M5757/69- New PIN M39016/10- 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 019 021 023 025 027 020 022 024 026 028 017 018 029 030 031 032 Support with PIN M39016/10019 021 023 025 027 034 035 036 037 038 017 033 029 039 031 040 Superseded PIN New PIN M39016/10- M39016/10001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030 031 032 Support with PIN M39016/10017 033 019 034 021 035 023 036 025 037 027 038 029 039 031 040 New PIN M39016/10033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048 Support with PIN M39016/10033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048 Referenced documents. In addition to MIL-PRF-39016, this document references the following: A-A-55485, /5 MIL-PRF-39016/11, /16, /21, /25, or /26 MIL-STD-202 MIL-STD-750 MIL-STD-1285 Changes from previous issue: Marginal notations are not used in this revision to identify changes with respect to the previous issue due to the extent of the changes. Custodians: Army - CR Navy - EC Air Force - 11 DLA - CC Preparing activity: DLA - CC Review activities: Army - AR Navy - AS, OS, SH Air Force - 19, 99 NSA - NS (Project 5945-1249) NOTE: The activities listed above were interested in this document as of the date of this document. Since organizations and responsibilities can change, you should verify the currency of the information above using the ASSIST Online database at http://assist.daps.dla.mil. 9