ARMY MIL-PRF-39005 G-2013 RESISTORS FIXED WIREWOUND (ACCURATE) NONESTABLISHED RELIABILITY ESTABLISHED RELIABILITY GENERAL SPECIFICATION FOR.pdf

1、INCH-POUND MIL-PRF-39005G 27 September 2013 SUPERSEDING MIL-PRF-39005F 8 May 2008 PERFORMANCE SPECIFICATION RESISTORS, FIXED, WIREWOUND (ACCURATE), NONESTABLISHED RELIABILITY, ESTABLISHED RELIABILITY GENERAL SPECIFICATION FOR This specification is approved for use by all Departments and Agencies of

2、the Department of Defense. 1. SCOPE 1.1 Scope. This specification covers the general requirements for nonestablished reliability (non-ER), established reliability (ER), accurate, wire-wound, fixed resistors that have a maximum resistance tolerance of 1 percent and a high degree of stability with res

3、pect to time under specified environmental conditions. The resistors are capable for continuous full-load (or voltage) operation at any ambient temperature up to 125C, and when derated, up to 145C (see 6.5). They are not capable for application where the alternating current (ac) characteristics are

4、of critical importance. ER resistors have life failure rates (FR) ranging from 1.0 percent to 0.001 percent per 1,000 hours (see 1.2.1.5). These FR are established at 60-percent confidence level on the basis of the life tests. The FR, identified by the appropriate symbol, is referred to operation at

5、 full rated voltage and temperature. 1.2 Classification. 1.2.1 Part or Identifying Number (PIN). PINs to be used for resistors acquired to this specification are created as follows (see 3.1 and 6.2): RBR52 L 12601 F S Style (1.2.1.1) Terminal (1.2.1.2) Resistance (1.2.1.3) Initial resistance toleran

6、ce (1.2.1.4) Product level designator (1.2.1.5) Comments, suggestions, or questions on this document should be addressed to: US Army Communications-Electronics Command, ATTN: RDER-PRO, Aberdeen Proving Grounds, MD 21015 or emailed to usarmy.apg.cerdec.mbx.standardization-crxmail.mil. Since contact i

7、nformation can change, you may want to verify the currency of this address information using the ASSIST Online database at https:/assist.dla.mil. AMSC N/A FSC 5905 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-39005G 2 1.2.1.1 Style. The st

8、yle is identified by the three letter symbol “RBR“ followed by a two digit number; the letters identify nonestablished reliability or established reliability, accurate, wire-wound, fixed resistors, and the number identifies the size and power rating of the resistors. 1.2.1.2 Terminal. The terminal i

9、s identified by a single letter in accordance with table I. TABLE I. Terminal. Symbol Terminal L U Solderable Weldable 1.2.1.3 Resistance. The nominal resistance is expressed in ohms and is identified by five digits; the first four digits represent significant figures and the last digit specifies th

10、e number of zeros to follow. When the values of resistance are less than 1,000 ohms, or when fractional values of an ohm are required, the letter “R“ is substituted for one of the significant digits to represent the decimal point. When the letter “R“ is used, succeeding digits of the group represent

11、 significant figures. The resistance value designations are shown in table II. Minimum and maximum resistance values are as specified (see 3.1). The standard values for every decade are follow the sequence demonstrated for “10 to 100“ decade in table III. The resistance values for 0.01-percent (T),

12、0.02-percent (Q), 0.05-percent (A), and 0.1-percent (B) resistance tolerances may be of any value within the limits of this specification, but it is preferred that the values be chosen from the 192-series decade specified in table III. TABLE II. Designation of resistance values. Designation Resistan

13、ce value (ohms) R1000 to R9880 inclusive 1R000 to 9R880 inclusive 10R00 to 98R80 inclusive 100R0 to 988R0 inclusive 10000 to 98800 inclusive 10001 to 98801 inclusive 10002 to 98802 inclusive 10003 to 98803 inclusive 0.10 to 0.988 inclusive 1.00 to 9.88 inclusive 10.00 to 98.80 inclusive 100.00 to 98

14、8.00 inclusive 1,000 to 9,880 inclusive 10,000 to 98,800 inclusive 100,000 to 988,000 inclusive 1,000,000 to 9,880,000 inclusive Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-39005G 3 TABLE III. Standard resistance values for the 10 decade

15、to 100 decade. Resistance tolerance Q T A B F Q T A B F Q T A B F Q T A B F Q T A B F Q T A B F 10.00 10.10 10.20 10.40 10.50 10.60 10.70 10.90 11.00 11.10 11.30 11.40 11.50 11.70 11.80 12.00 12.10 12.30 12.40 12.60 12.70 12.90 13.00 13.20 13.30 13.50 13.70 13.80 14.00 14.20 14.30 14.50 10.00 - 10.2

16、0 - 10.50 - 10.70 - 11.00 - 11.30 - 11.50 - 11.80 - 12.10 - 12.40 - 12.70 - 13.00 - 13.30 - 13.70 - 14.00 - 14.30 - 14.70 14.90 15.00 15.20 15.40 15.60 15.80 16.00 16.20 16.40 16.50 16.70 16.90 17.20 17.40 17.60 17.80 18.00 18.20 18.40 18.70 18.90 19.10 19.30 19.60 19.80 20.00 20.30 20.50 20.80 21.0

17、0 21.30 14.70 - 15.00 - 15.40 - 15.80 - 16.20 - 16.50 - 16.90 - 17.40 - 17.80 - 18.20 - 18.70 - 19.10 - 19.60 - 20.00 - 20.50 - 21.00 - 21.50 21.80 22.10 22.30 22.60 22.90 23.20 23.40 23.70 24.00 24.30 24.60 24.90 25.20 25.50 25.80 26.10 26.40 26.70 27.10 27.40 27.70 28.00 28.40 28.70 29.10 29.40 29

18、.80 30.10 30.50 30.90 31.20 21.50 - 22.10 - 22.60 - 23.20 - 23.70 - 24.30 - 24.90 - 25.50 - 26.10 - 26.70 - 27.40 - 28.00 - 28.70 - 29.40 - 30.10 - 30.90 - 31.60 32.00 32.40 32.80 33.20 33.60 34.00 34.40 34.80 35.20 35.70 36.10 36.50 37.00 37.40 37.90 38.30 38.80 39.20 39.70 40.20 40.70 41.20 41.70

19、42.20 42.70 43.20 43.70 44.20 44.80 45.30 45.90 31.60 - 32.40 - 33.20 - 34.00 - 34.80 - 35.70 - 36.50 - 37.40 - 38.30 - 39.20 - 40.20 - 41.20 - 42.20 - 43.20 - 44.20 - 45.30 - 46.40 47.00 47.50 48.10 48.70 49.30 49.90 50.50 51.10 51.70 52.30 53.00 53.60 54.20 54.90 55.60 56.20 56.90 57.60 58.30 59.0

20、0 59.70 60.40 61.20 61.90 62.60 63.40 64.20 64.90 65.70 66.50 67.30 46.40 - 47.50 - 48.70 - 49.90 - 51.10 - 52.30 - 53.60 - 54.90 - 56.20 - 57.60 - 59.00 - 60.40 - 61.90 - 63.40 - 64.90 - 66.50 - 68.10 69.00 69.80 70.60 71.50 72.30 73.20 74.10 75.00 75.90 76.80 77.70 78.70 79.60 80.60 81.60 82.50 83

21、.50 84.50 85.60 86.60 87.60 88.70 89.80 90.90 92.00 93.10 94.20 95.30 96.50 97.60 98.80 68.10 - 69.80 - 71.50 - 73.20 - 75.00 - 76.80 - 78.70 - 80.60 - 82.50 - 84.50 - 86.60 - 88.70 - 90.90 - 93.10 - 95.30 - 97.60 - 1.2.1.4 Initial resistance tolerance. The initial resistance tolerance is identified

22、 by a single letter in accordance with table IV. TABLE IV. Initial resistance tolerance and applicable minimum resistance values. Symbol Initial resistance tolerance (at 25C 2C) Minimum resistance values (see 3.1) T Q A B F Percent () 0.01 0.02 0.05 0.10 1.00 Ohms 10.0 10.0 10.0 10.0 0.10 Provided b

23、y IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-39005G 4 1.2.1.5 Product level designator. The product level designator is specified in table V by a single letter which identifies nonestablished reliability or established reliability resistors. TABLE V

24、. Product level designator. Product level designator Product level C M P R S Non-ER 1/ 1.0 1/ 0.1 1/ 0.01 1/ 0.001 1/ Failure rate level (FRL) in percent per 1,000 hours. 2. APPLICABLE DOCUMENTS * 2.1 General. The documents listed in this section are specified in sections 3, 4 and 5 of this specific

25、ation. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements

26、 documents cited in sections 3, 4 and 5 of this specification, whether or not they are listed. 2.2 Government documents. 2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwis

27、e specified, the issues of these documents are those cited in the solicitation or contract. DEPARTMENT OF DEFENSE SPECIFICATIONS (See supplement 1 for a list of associated specifications.) DEPARTMENT OF DEFENSE STANDARDS MIL-STD-202 - Electronic and Electrical Component Parts, Test Methods for. MIL-

28、STD-690 - Failure Rate Sampling Plans and Procedures. MIL-STD-790 - Standard Practice for Established Reliability and High Reliability Qualified Products List (QPL) Systems for Electrical, Electronic, and Fiber Optic Parts Specifications. MIL-STD-810 - Environmental Engineering Considerations and La

29、boratory Tests. MIL-STD-1276 - Leads for Electronic Component Parts. MIL-STD-1285 - Marking of Electrical and Electronic Parts. * (Copies of these documents are available online at http:/quicksearch.dla.mil or from the DLA Document Services, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-50

30、94.) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-39005G 5 2.3 Non-government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents which

31、are those listed in the solicitation or contract. * TECHAMERICA EIA-554-1 - Assessment of Outgoing Nonconforming Levels in Parts Per Million (PPM). EIA-557 - Statistical Process Control Systems (SPC). * (Copies of these documents are available online at www.techamerica.org or from TechAmerica, 601 P

32、enn NW, North Building, Suite 600, Washington DC, 20004-2650.) * 2.4 Order of precedence. Unless otherwise noted herein or in the contract, or in the event of a conflict between the text of this document and the references cited herein (except for related specification sheets), the text of this docu

33、ment takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 3. REQUIREMENTS 3.1 Specification sheets. The individual item requirements shall be as specified herein and in accordance with the applicable specificat

34、ion sheet. In the event of any conflict between the requirements of this specification and the specification sheet, the latter shall govern (see 6.2). 3.2 Qualification. The resistors furnished under this specification shall be products which are authorized by the qualifying activity for listing on

35、the applicable Qualified Products List (QPL) at the time of award of contract (see 4.4 and 6.3). In addition, the manufacturer shall obtain certification from the qualifying activity that the reliability and quality requirements of 4.2 have been met and are being maintained. Authorized distributors

36、that are approved to MIL-STD-790 distributor requirements by the QPL manufacturer are listed in the QPL. 3.3 QPL system. The manufacturer shall establish and maintain a QPL system for parts covered by this specification. Requirements for this system are specified in MIL-STD-790 (all product levels)

37、and MIL-STD-690 (ER parts only). In addition, the manufacturer shall also establish a Statistical Process Control (SPC) and Part Per Million (ppm) system that meets the requirements as described in 3.3.1 and 3.3.2 respectively. 3.3.1 SPC system. As part of the overall MIL-STD-790 QPL system, the man

38、ufacturer shall establish a SPC system that meets the requirements of EIA-557. Typical manufacturing processes for application of SPC include formation of resistance elements, weld strength, trimming, and termination. In addition, the manufacturer shall demonstrate resistance temperature characteris

39、tic (RTC) control in the process. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-39005G 6 3.3.2 PPM system. As part of the overall MIL-STD-790 QPL system, the manufacturer shall establish a ppm system for assessing the average outgoing quali

40、ty of lots in accordance with EIA-554-1 and 4.6.4. Data exclusion, in accordance with EIA 554-1, may be used with approval of the qualifying activity. The PPM system shall identify the PPM rate at the end of each month and shall be based on a six month moving average. PPM and dc resistance shall be

41、assessed for each style. Style reporting may include both non-ER and ER style combinations. 3.4 Material. The material shall be as specified herein. However, when a definite material is not specified, a material shall be used which will enable the resistors to meet the performance requirements of th

42、is specification. Acceptance or approval of any constituent material shall not be construed as a guaranty of the acceptance of the finished product. 3.5 Interface and physical dimension requirements. Resistors shall meet the interface and physical dimensions as specified (see 3.1). The resistor asse

43、mbly shall be protected by a coating or enclosure of moisture resistant insulation material which shall withstand exposure to the humidity and temperature conditions specified herein. In order to minimize inductance, resistors shall be wound by reverse pi-winding, bifilar, or equivalent method. 3.5.

44、1 Terminals. Terminals shall be made of a solid conductor of the length and diameter specified (see 3.1). The terminals shall be solderable in accordance with method 208 of MIL-STD-202. 3.5.1.1 Solderable terminals. Solderable terminals shall be treated to meet the requirements of solderability (see

45、 3.10). 3.5.1.2 Weldable terminals. Weldable terminals shall be as specified in table I. The manufacturer shall verify by certification that the weldable leads meet all the applicable requirements of MIL-STD-1276 (see 3.1). The solderability requirement of 3.10 is not applicable to weldable terminal

46、s. 3.5.2 Pure tin. The use of pure tin, as an underplate or final finish is prohibited both internally and externally. Tin content of resistor components and solder shall not exceed 97 percent, by mass. Tin shall be alloyed with a minimum of 3 percent lead, by mass (see 6.11). 3.5.3 Solder dip (reti

47、nning) leads. The manufacturer (or their authorized category B or category C distributor) may solder dip/retin the leads of product supplied to this specification provided the solder dip process (see appendix A) has been approved by the qualifying activity. 3.5.4 Protective coating or enclosure. Res

48、istor assemblies shall be protected by a coating or enclosure of moisture resistant insulating material which shall completely cover the exterior of the resistance element, including connections or terminations. The coating shall not crack, craze, drip, run, or form globules of any temperature up to and including 145C, regardless of the mounting position o