1、INCH-POUND MIL-PRF-83536D 2 January 2013 SUPERSEDING MIL-PRF-83536C 15 March 2012 PERFORMANCE SPECIFICATION RELAYS, ELECTROMAGNETIC, ESTABLISHED RELIABILITY, 25 AMPERES AND BELOW, GENERAL SPECIFICATION FOR This specification is approved for use by all Departments and Agencies of the Department of De
2、fense. 1. SCOPE 1.1 Scope. This specification covers the general requirements for electromagnetic, hermetically sealed relays for use in aircraft, missile, spacecraft, ship, and other primary vehicles or in ground support equipment (see 6.1). These relays are designed to operate over the full range
3、from low level to power switching with contact ratings up to 25 amperes alternating current (ac) or direct current (dc). Specification sheets (see 3.1) specifying requirements for 25 ampere relays are for relays that have a maximum load rating of 25 amperes for resistive load only. All other load ra
4、tings (motor, inductive, lamp) are less than 25 amperes. The failure rate (FR) level is established at a confidence level of 90 percent for qualification and 60 percent for maintenance of qualification based on 100,000 cycles at +125C under the rated load conditions specified herein. For application
5、 and caution information, see 6.1. 1.2 Part or Identifying Number (PIN). The PIN consists of the letter “M“, the basic number of the specification sheet, an assigned dash number (see 3.1), and a suffix letter designating FR level (see table I) as shown in the following example: M83536 /10 -001 L Spe
6、cification designator Specification sheet number Dash number Failure rate level 1.3 FR level designation. The FR level designation is shown in table I (see 4.6 and 6.1). TABLE I. FR level designation. FR level designation FR level (percent per 10,000 cycles) L M P R 3.0 1.0 0.1 0.01 Comments, sugges
7、tions or questions on this document should be addressed to DLA Land and Maritime, ATTN: VAT, Post Office Box 3990, Columbus, OH 43218-3990, or emailed to relaydla.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online databa
8、se at https:/assist.dla.mil. AMSC N/A FSC 5945 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-83536D 2 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed in this section are specified in sections 3 and 4 of this specification. This se
9、ction 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 of documents
10、cited in sections 3 and 4 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 otherwise specified, t
11、he issues of these documents are those cited in the solicitation or contract. DEPARTMENT OF DEFENSE SPECIFICATION MIL-DTL-12883 - Sockets and Accessories for Plug-in Electronic Components, General Specification for. (See supplement 1 for list of specification sheets.) DEPARTMENT OF DEFENSE STANDARDS
12、 MIL-STD-202 - Test Method for Electronic and Electrical Component Parts. MIL-STD-690 - Failure Rate Sampling Plans and Procedures. MIL-STD-750 - Test Methods for Semiconductor Devices. MIL-STD-790 - Standard Practice for Established Reliability and High Reliability Qualified Products List (QPL) Sys
13、tems for Electrical, Electronic, and Fiber Optic Parts Specifications MIL-STD-883 - Test Method Standard, Microcircuits. MIL-STD-1276 - Leads for Electronic Component Parts. MIL-STD-1285 - Marking of Electrical and Electronic Parts. DEPARTMENT OF DEFENSE HANDBOOK MIL-HDBK-454 - General Guidelines fo
14、r Electrical Equipment. (Copies of these documents are available online at https:/assist.dla.mil/quicksearch or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.) 2.3 Non-Government publications. The following documents form a part of this do
15、cument to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) ANSI/IEEE Y32.2 - Graphic Symbols for Electrical and Electronic Diagrams. NCSL - Z540.3 - Laboratories, Calib
16、ration, and Measuring and Test Equipment. INTERNATIONAL STANDARDS ORGANIZATION (ISO) ISO-10012 - Measurement management systems- Requirements for Measurement Processes and Measuring Equipment. (Application for copies should be requested online at http:/www.ansi.org or from the American National Stan
17、dards Institute, Incorporated, 11 West 42nd Street, New York, NY 10036-8002.) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-83536D 3 JEDEC EIA-557-B - Statistical Process Control Systems. (Application for copies should be requested online a
18、t http:/www.jedec.org or from JEDEC, 3103 North 10thStreet, Suite 240-S, Arlington, VA 22201-2107.) SOCIETY OF AUTOMOTIVE ENGINEERS (SAE) SAE-AMS2422 - Plating, Gold, Electronic and Electrical Applications. SAE-AMS-QQ-N-290 - Nickel Plating (Electrodeposited). (Application for copies should be reque
19、sted online at http:/www.sae.org or from the Society of Automotive Engineers, 400 Commonwealth Drive, Warrendale, Pennsylvania, 15096-0001.) 2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cite
20、d herein (except for related specification sheets), the text of this document 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 shal
21、l be as specified herein and in accordance with the applicable specification sheet. In the event of any conflict between the requirements of this specification and the specification sheet, the latter shall govern. 3.2 Qualification. Relays furnished under this specification shall be products that ar
22、e authorized by the qualifying activity for listing on the applicable qualified products list (QPL) before contract award (see 4.4 and 6.3). Authorized distributors which are approved to MIL-STD-790 distributor requirements by the QPL manufacturers are listed in the QPL. 3.3 QPL system. The manufact
23、urer shall establish and maintain a QPL system for parts covered by this specification. Requirements for this system are specified in MIL-STD-790 and MIL-STD-690 with details and exceptions specified in 4.2.1, 4.4.4, and 4.5. The confidence level for qualification is 90 percent and the confidence le
24、vel for maintenance of qualification is 60 percent. In addition, the manufacturer shall also establish a Statistical Process Control (SPC) system that meets the requirements as described in 3.3.1. 3.3.1 SPC. The contractor shall implement and use SPC in the manufacturing process for parts covered by
25、 this specification. The SPC program shall be developed and maintained in accordance with EIA-557-B or an equivalent system as approved by the qualifying activity. The SPC program shall be documented and maintained as part of the overall product assurance program as specified in MIL-STD-790. 3.4 Mat
26、erials. Materials used externally shall be fungus inert (see guideline 4 of MIL-HDBK-454), self-extinguishing, and shall not support combustion, nor give off noxious gases in harmful quantities. Materials used internally shall not give off gases in quantities sufficient to cause explosion of sealed
27、enclosures, cause contamination of the contacts or other parts of the relay that will adversely affect life or reliability, or form current-carrying tracks when subjected to any of the tests specified herein. Ceramic used for external surfaces shall be glazed. The use of silicone (see 6.12) or silic
28、one compounds for any purpose is prohibited. The selection of materials shall be such as to provide maximum shelf life. Acceptance or approval of any constituent material shall not be construed as a guaranty of the acceptance of the finished product. 3.4.1 Metals. Metals shall be of a corrosion-resi
29、stant type or shall be plated or treated to resist corrosion. The use of mercury or mercury compounds is prohibited. The use of magnesium or magnesium alloys is prohibited (not applicable to contact systems). Provided by IHSNot for ResaleNo reproduction or networking permitted without license from I
30、HS-,-,-MIL-PRF-83536D 4 3.4.1.1 Plated finishes. a. Pure tin plating is prohibited internally and externally (see 6.6.1). Use of tin-lead finishes are acceptable provided that the minimum lead content is 3 percent. Other tin-lead alloys are acceptable as approved by the qualifying activity. b. Pure
31、zinc plating is prohibited internally and externally. c. Pure cadmium plating is prohibited internally and externally. 3.4.1.2 Dissimilar metals. When dissimilar metals are used in intimate contact with each other, protection against electrolysis and corrosion shall be provided. The use of dissimila
32、r metals in contact, which tends toward active electrolytic corrosion (particularly brass, copper, or steel used in contact with aluminum or aluminum alloy), is not acceptable. However, metal spraying or metal plating of dissimilar base metals to provide similar or suitable abutting surfaces is perm
33、itted. Dissimilar metals should be as defined in 6.6. In hermetic seals, the 0.25 volt difference between the header material and the housing material is not applicable. 3.4.2 Magnet wire. Magnet wire used shall enable the relay to meet the performance requirements of this specification. 3.5 Interfa
34、ce and construction requirements. Relays shall meet the interface and construction requirements as specified in 3.1 (weight, physical dimensions.). 3.5.1 Case. Unless otherwise specified (see 3.1), the case shall not be electrically connected to the contacts or coil; however, it may be used as part
35、of the magnetic circuit. 3.5.1.1 Case grounding. When specified (see 3.1), means for connecting the relay case to ground shall be provided. 3.5.2 Sealing process. Relays shall be dried, degassed, and backfilled with an atmosphere and sealed by welding such that the requirements of this specification
36、 are met. Adjunct sealant shall only be applied to relays that have initially passed the gross leak seal requirement of this specification. Adjunct sealant (see 6.12), if used, must comply with the following characteristics: a. Shall not extend above 20 percent of the length of the exposed terminals
37、 above the glass meniscus. b. Trace color is permitted if it is a natural result of the sealant process. c. Shall form, after curing, a permanent nonconductive, non-cracking seal under all relay environments. After the cover has been welded to the header, no rework shall be performed that requires r
38、emoval of this cover from the header. 3.5.3 Contacts. Contacts shall have load ratings and arrangements (see MIL-STD-1285) as specified (see 3.1) and unless otherwise specified (see 3.1), shall be capable of carrying the maximum rated current continuously as well as making and breaking the specified
39、 current under all environmental conditions specified herein. 3.5.4 Coils. Coils shall be adequately insulated electrically from the contacts and the case. The resistance and rated voltage (or current) shall be as specified (see 3.1). Unless otherwise specified (see 3.1), coils shall be designed for
40、 continuous operation at maximum rated voltage and temperature. 3.5.4.1 Stabilization of permanent magnets. Permanent magnets and magnetic assemblies shall be artificially aged to minimize decay of flux levels. The residual induction (flux) in permanent magnetic assemblies shall be reduced to a leve
41、l where it will not be affected by demagnetizing forces encountered in normal service, handling, and any tests specified herein. The retraceability characteristics shall be compatible with all performance requirements of the relays. 3.5.4.2 Coil terminal identification. Terminal identification shall
42、 be marked as specified and in accordance with MIL-STD-1285. When specified, a bead of contrasting color shall be used to designate the X1 (positive, if applicable) terminal (see figure 1 and MIL-STD-1285) (see 3.1). Provided by IHSNot for ResaleNo reproduction or networking permitted without licens
43、e from IHS-,-,-MIL-PRF-83536D 5 FIGURE 1. Symbols and markings for terminals. 3.5.4.3 Latching relays. Latching relays with two coils shall be so designed that if both coils are energized simultaneously, the contacts shall not achieve a neutral position (both the normally closed and normally open co
44、ntacts are open). The relay shall be screened as specified in 3.12.8 and 4.8.7.7. Specified dropout and hold values (voltage or current) and release time are not applicable to latching relays. 3.5.5 Circuit diagram. The circuit diagram as specified shall be a terminal view. Circuit symbols shall be
45、in accordance with ANSI Y32.2. For relays without an orientation tab, the circuit diagram, as specified (see 3.1) shall be orientated so that when the relay is held with the circuit diagram right side up as shown, and rotated away from the viewer about a horizontal axis through the diagram until the
46、 header terminals face the viewer, then each terminal shall be in the location shown in the circuit diagram. 3.5.6 Mounting means (see 3.1). 3.5.6.1 Bracket. Mounting brackets shall be an integral part of the relay, securely attached thereto in a manner to prevent any movement between the relay and
47、the mounting bracket. 3.5.7 Terminals. Terminals shall be as specified (see 3.1). Manufacturer may supply hot solder dipped terminals provided that the hot solder dipping process has been approved by the qualifying activity and when specified on the individual order. Solder dipped terminals may be .
48、003 inch (0.762 mm) larger than the maximum diameter specified (see 3.1). Icicles are a normal result of the hot solder dip process and shall not be grounds for rejection (see figure 2). Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-PRF-83536D
49、6 NOTES: 1. No solder is allowed on the header surface. Components (relay terminals) after solder-dip shall be capable of meeting method 208 of MIL-STD-202, solderability requirements. 2. Solder-coat thickness shall be .0001 inch (.00254 mm) minimum. FIGURE 2. Solder-dip acceptability criteria (solder-icicle length limits). 3.5.7.1 Solder-hook terminals. Solder-hook terminals shall be designed to accommodate two conductors, each rate
