*R oH VE S CO AV R M AI SIO PL LA N IA BL S NT E Features Features one-piece molded plastic shaft and rotor assembly Available in a variety of pin-out configurations Virtually infinite electrical circuit isolation Model 96 sealed for board wash Metal shaft available as special feature RoHS compliant versions available* 91, 92, 93, 94, 95, 96, 99 - 5/8 " Square Single-Turn Panel Control 99 - 5/8 " Square Single-Turn Panel Control with Rotary Switch Potentiometer Specifications Initial Electrical Characteristics1 Conductive Plastic Element Cermet Element Standard Resistance Range Linear Tapers (A, B, E, & H) ................................................................(B & E) 1 K ohms to 1 megohm ......................(A & H) 100 ohms to 1 megohm Audio Tapers (C, D, F, G, S, & T).........................................................(D,G,S, & T) 1 K ohms to 1 megohm ..............(C & F) 1 K ohms to 1 megohm Total Resistance Tolerance .....................................................................10 % or 20 % .................................................5% or 10% Independent Linearity .............................................................................5 %...............................................................5 % Absolute Minimum Resistance ...............................................................2 ohms maximum........................................... 2 ohms maximum Effective Electrical Angle ........................................................................(Linear tapers) 240 5 ...............................(Linear tapers) 240 6 (Audio tapers) 225 5 (Audio tapers) 225 6 Contact Resistance Variation .................................................................1 %...............................................................1 % or 3 ohms (whichever is greater) Dielectric Withstanding Voltage (MIL-STD-202, Method 301) Sea Level............................................................................................1,500 VAC minimum.......................................1,500 VAC minimum 70,000 Feet ........................................................................................500 VAC minimum..........................................500 VAC minimum Insulation Resistance (500 VDC) ............................................................1,000 megohms minimum..............................1,000 megohms minimum Power Rating (Voltage Limited By Power Dissipation or 350 VAC, Whichever Is Less) +70 C Single Section Assembly .......................................................(Linear tapers) 0.5 watt...................................(Linear tapers) 2 watts (Audio tapers) 0.25 watt (Audio tapers) 1 watt +70 C Multiple Section Assembly.....................................................(Linear tapers) 0.5 watt/section......................(Linear tapers) 1 watt/section (Audio tapers) 0.25 watt/section (Audio tapers) 0.5 watt/section +125 C ..............................................................................................0 watt..............................................................0 watt Theoretical Resolution ............................................................................Essentially infinite ...........................................Essentially infinite Environmental Characteristics1 Operating Temperature Range ...............................................................-40 C to +125 C...........................................-40 C to +125 C Storage Temperature Range...................................................................-55 C to +125 C...........................................-55 C to +125 C Temperature Coefficient Over Storage Temperature Range...................1,000 ppm/C...............................................150 ppm/C Vibration (Single Section)........................................................................15 G................................................................15 G Total Resistance Shift.........................................................................2 % maximum ..............................................2 % maximum Voltage Ratio Shift..............................................................................5 % maximum ..............................................5 % maximum Shock (Single Section)............................................................................30 G................................................................30 G Total Resistance Shift.........................................................................2 % maximum ..............................................2 % maximum Voltage Ratio Shift..............................................................................5 % maximum ..............................................5 % maximum Load Life.................................................................................................1,000 hours ....................................................1,000 hours Total Resistance Shift.........................................................................10 % maximum ............................................5 % maximum Rotational Life (No Load) ........................................................................100,000 cycles ...............................................100,000 cycles Total Resistance Shift.........................................................................(Linear tapers) 10 ohms or 15 % TRS max. ...(All tapers) 5 % TRS max. (whichever is greater) (Audio tapers) 20 % maximum Contact Resistance Variation @ 50,000 cycles ..................................(Linear tapers) 2 %.......................................2 % (Audio tapers) 3 % .......................................3 % Moisture Resistance (MIL-STD-303, Method 103, Condition B) Total Resistance Shift.........................................................................(Linear tapers) 10 % TRS maximum ............(All tapers) 5 % TRS maximum (Audio tapers) 20 % TRS maximum Insulation Resistance (500 VDC) ........................................................100 megohms minimum.................................100 megohms minimum IP Rating (Model 96) ...............................................................................IP 65 ...............................................................IP 65 (All Others)..........................................................................................IP 40 ...............................................................IP 40 *RoHS Directive 2002/95/EC Jan 27 2003 including Annex Specifications are subject to change without notice. Customers should verify actual device performance in their specific applications. 91, 92, 93, 94, 95, 96, 99 - 5/8 " Square Single-Turn Panel Control 99 - 5/8 " Square Single-Turn Panel Control with Rotary Switch Potentiometer Specifications Mechanical Characteristics1 Stop Strength (1/4 " D shaft)......................................................................................................................................................................45.19 N-cm (4 lb.-in.) (1/8 " D shaft) ....................................................................................................................................................................33.89 N-cm (3 lb.-in.) Mechanical Angle ........................................................................................................................................................................................................300 5 Torque Starting ....................................................................................................................................................................0.3 max. above average running torque Running Torque Single or Dual Section (A ,D & R Bushings) ..............................................................................................................0.21 to 1.06 N-cm (0.3 to 1.5 oz.-in.) Single or Dual Section (C & U Bushings) ..................................................................................................................0.14 to 1.06 N-cm (0.2 to 1.5 oz.-in.) Mounting ............................................................................................................................................(Metal Bushing) 1.7-2.0 N-m (15-18 lb.-in.) maximum Plastic Bushing) 56-79 N-cm (5-7 lb.-in.) maximum Variation ................................................................................................................................................0.35 N-cm (0.5 oz.-in.) maximum in 45 shaft travel Weight (Single Section) ..................................................................................................................................................................................7 grams maximum (Each Additional Section) ..........................................................................................................................................................................4 grams maximum Terminals ........................................................................................................................................................Printed circuit terminals, J-Hooks or solder lugs Soldering Condition ......................................................................Recommended hand soldering using Sn95/Ag5 no clean solder, 0.025 " wire diameter. Maximum temperature 399 C (750 F) for 3 seconds. No wash process to be used with no clean flux. Marking............................................................................................................Manufacturer's trademark, date code, resistance, manufacturer's part number Ganging (Multiple Section Potentiometers) ....................................................................................................................................................2 cups maximum Hardware ............................................One lockwasher and one mounting nut is shipped with each potentiometer, except where noted in the part number. NOTE: ALL MODEL 90 PERFORMANCE SPECIFICATIONS DO NOT APPLY TO UNITS SUBJECTED TO PRINTED CIRCUIT BOARD CLEANING PROCEDURES, EXCEPT FOR THE SEALED VERSION (MODEL 96). 1 AT ROOM AMBIENT: +25 C NOMINAL AND 50 % RELATIVE HUMIDITY NOMINAL, EXCEPT AS NOTED. Specifications are subject to change without notice. Customers should verify actual device performance in their specific applications. 91, 92, 93, 94, 95, 96, 99 - 5/8 " Square Single-Turn Panel Control 99 - 5/8 " Square Single-Turn Panel Control with Rotary Switch Rotary Switch Specifications Initial Electrical Characteristics1 Contacts: DPST ..................................................................................................................................................................................N.O/N.O., N.C./N.C. or N.O./N.C. DPDT....................................................................................................................................................................................2 N.O./N.C. (break before make) Power Rating (Resistive Load): DPST ................................................................................................................2 A @ 125 volts RMS-60 Hz or 2 A @ 28 VDC, 1 A @ 250 volts RMS-60 Hz DPDT ..............................................................................................................................................................1 A @ 125 volts RMS-60 Hz or 1 A @ 28 VDC Contact Resistance (0.1 VDC-10 mA)........................................................................................................................................................10 milliohms nominal Contact Bounce ..................................................................................................................................................................................5 milliseconds maximum Dielectric Withstanding Voltage (MIL-STD-202, Method 301) Sea Level ................................................................................................................................................................................................1500 VAC minimum Insulation Resistance ..........................................................................................................................................................................1000 megohms minimum Environmental Characteristics1 Operating Temperature Range ............................................................................................................................................................................0 C to +70 C Exposure Temperature Range ........................................................................................................................................................................-65 C to +125 C Vibration (Dual Section)..........................................................................................................................................................................................................8 G Contact Resistance ............................................................................................................................................................................10 milliohms maximum Contact Bounce..............................................................................................................................................................................0.1 millisecond maximum Shock (Dual Section)............................................................................................................................................................................................................20 G Contact Resistance ............................................................................................................................................................................10 milliohms maximum Contact Bounce..............................................................................................................................................................................0.1 millisecond maximum Rotational Life........................................................................................................................................................................................................25,000 cycles Switch Actuating Torque (50% Duty cycle @ Rated Power Load) ......................................................................................1.41 to 4.94 N-cm (2 to 7 oz.-in.) Contact Resistance ..........................................................................................................................................................................100 milliohms maximum Moisture Resistance (MIL-STD-202, Method 106, Condition B) Contact Resistance (0.1 VDC-10 mA) ................................................................................................................................................10 milliohms maximum Insulation Resistance (After 24 Hours @ Room Temperature) (500 VDC) ........................................................................................100 megohms minimum Housing Material................................................................................................................................High temperature, flame retardant, thermosetting plastic Mechanical Characteristics1 Actuating Torque (Each Section, Switch Module Only) ......................................................................................................3.53 to 10.59 N-cm (5 to 15 oz.-in.) Running Torque (Out of Detent, 2-4 Module Assembly) ......................................................................................................0.21 to 1.41 N-cm (0.3 to 2 oz.-in.) Detent ......................................................................................................................................................................................................CW or CCW standard Actuation Angle..............................................................................................................................................................................................................20 5 Contact Materials ............................................................................................................................................................................Fine silver with gold overlay Terminal Styles ....................................................................................................................................................................................................Solder lug only Standard Orientation ..................................................................................................................................................................In-line with control terminals Optional..............................................................................................................................................................................Rotated 90 CCW from standard Terminal Strength (Before and After Soldering Heat Exposure) ............................................................................................................0.9 kg (2 lbs.) minimum NOTE: Model 99 performance specifications do not apply to units subjected to printed circuit board cleaning procedures. 1 At room ambient: +25 C nominal and 50 % relative humidity nominal, except as noted. Specifications are subject to change without notice. Customers should verify actual device performance in their specific applications. 91, 92, 93, 94, 95, 96, 99 - 5/8 " Square Single-Turn Product Dimensions Model 92 J-Hooked Terminals, In-Line Model 91 PC Pin Terminals, In-Line .79 .41 (.031 .016) 22.86 .43 (.90 .017) 12.7 (.50) 15.88 .38 (.625 + .015) 1.37 (.054) 9.53 .38 (STYLE A) (.375 .015) 6.35 .38 (STYLE C) (.250 .015) SEE DETAIL FOR SHAFT OPTIONS .79 (.031) 2 PLCS. 13.72 DIA. (.54) 1 2 11.05 .20 (.435 .008) 2.54 (.100) 10.16 (.40) .254 (.010) GAP 3 2 1 5.08 (.20) 3 9.53 .38 (.375 .015) 15.29 .56 (.602 .022) (MODEL 91 ONLY) 1.52 (.06) .81 DIA. (.032) 2.54 (.100) .81 (.032) R. MAX. 12.7 1.02 (.50 .040) 5.97 .38 (.235 .015) 5.08 .38 (.20 .015)TYP. 16.89 .51 (.665 .020) 2 1.52 (.06) GAP 5.33 .76 (.21 .03) 3.81 (.150) MAX. TYP. 6 2 3 2.29 6 PLCS. (.090) 2.77 .38 (.109 .015) 4.45 .38 (.175 .015) Switch Module Variations Shaft Flat Orientation 120 5 STD. FLAT ORIENTATION (SHAFT AT CCW END) 3/8 THREADLESS (9.53 mm) (STYLE "D") 3/8-32 UNEF (9.53 mm) (STYLE "A") 1/4-32 UNEF (6.35 mm) (STYLE "C") M10 X 0.75-6g (STYLE "R") M7 X 0.75-6g (STYLE "U") 1 CCW 3 2 POTENTIOMETER TOTAL ROTATION 300 CCW DETENT 25 MAX. ACTUATION ANGLE (TYPES 51, 53, 55, 57, 59, 61, 71, 73) 1 2 3 1 2.41 X 1.14 SLOT 6 PLCS (.095 .045) 1 Bushing Styles 5.08 (.20) 11.05 .20 (.435 .008) 1 3 MOUNTING SURFACE 4 5 Model 93 PC Pin Terminals, "L" Pattern 10.16 .30 (.40 .012) 15.88 (.625) REF. 5.59 .38 (.022 .015) Model 94 J-Hooked Terminals, "L" Pattern 3 2 1 .81 DIA. TYP. (.032) 24.77 .51 (.975 .020) 2.77 .38 (1.09 .015) 15.88 .38 (.625 .015) 2.36 (.093) Model 99 1st Cup Same As Model 95 (2nd Cup - Switch) 2 CW DETENT 25 MAX. ACTUATION ANGLE (TYPES 50, 52, 54, 56, 58, 60, 70, 72) Model 95 Solder Lug Terminals, "Triangular" Pattern NOTE: Switch terminals shown in vertical position. 5.08 1.02 (.200 .040) 1 5.59 .20 (.220 .008) 4.45 .38 (.175 .015) 10.16 (.40) 2.54 (.100) .41 (.016) 2 1 2 DPST (NC/NC) (TYPES 54, 55, 60, 61) 4 3 2.29 1.02 WIDE X LONG (.040) (.090) 3 PLCS. 4 2 1 3 1 DPST (NO/NO) (TYPES 52, 53, 58, 59) 2 1 2.54 (.100) 3 DPST (NO/NC) (TYPES 50, 51, 56, 57) 3 3 2 1 4.45 .38 (.175 .015) 2.03 (.080) 3 PLCS. 4 4 3 5 6 2 DPST (NC/NC) (TYPES 70, 71, 72, 73) Switch contacts shown in detent position. Shaft Styles 1.60+.38/-.00 (.063+.015/-.000) SEE NOTE 1.19 (.047) 14.27 .25 (.562 .010) SHAFT TYPE "B" 12.7 15.88 19.05 22.23 6.31+.025/-.076 DIA STD. LENGTHS "L" (1/2), (5/8), (3/4), (7/8) (.2485+.001/.003) USES BUSHING A OR D 6.31+.025/-.076 DIA. (.2485+.001/.003) 5.49 (.216) 6.31+.025/-.076 DIA. (.2485+.001/.010) SHAFT TYPE "C" 19.05 22.0 STD. LENGTHS "L" (3/4), (7/8) USES BUSHING A OR D Specifications are subject to change without notice. Customers should verify actual device performance in their specific applications. .79 (0.03) SHAFT TYPE "R" 16.0 19.05 22.0 STD. LENGTHS "L" (5/8), (3/4), (7/8) USES BUSHING R 1.00 6.0 (.04) (.236)DIA. 3.988 DIA. (.157) *DIMENSIONS ARE IN MM DIMENSIONS ARE: SHAFT TYPE "D" 12.7 15.88 STD. LENGTHS "L" (1/2), (5/8), 19.05 USES BUSHING C (3/4) 1.80 .25 (0.07 .001) 1.50 .25 (0.06 .001) SHAFT TYPE "W" STD. LENGTHS "L" 1" FINGER KNURL, FOR USE WITH BUSHING A OR D .128 TOLERANCES EXCEPT AS SHOWN: DECIMAL .XXX (.015 )FRACTION 1/64 .005 .XX ANGLE 5 (.38) 13.16+.00/-.15 DIA. (.1245+.000/-.006) MM (INCHES) SHAFT TYPE "T" 22.0 12.0 16.0 STD. LENGTHS "L" (1/2), (5/8), (7/8) USES BUSHING U 7.95 19.05 NOTE: FOR (.750) SHAFT - FLAT LENGTH IS (.313) 22.23 11.18 FOR (.875) SHAFT - FLAT LENGTH IS (.440) How to Order 90 Series Panel Controls 91 A 2 A - B 28 - A 15 / A15 L Models 91 - 96: Part number for multiple section potentiometers must have a taper and resistance value for each section. 99 A 2 A - B 28 - A 15 / R51 L Models 97 & 99: Part number must contain a switch type. POTENTIOMETER TYPE L RoHS Compliant Blank Standard ANTI-ROTATION LUG A Single .305 (7.8 mm) R, 90 CW C Single .305 " (7.8 mm) R, 270 CW D No Lug # SECTIONS 1 Single 2 Dual SWITCH TYPE (MODELS 97 & 99 ONLY) (R50) DPST N.O./N.C. CW Detent In-Line Term (R51) DPST N.O./N.C. CCW Detent In-Line Term (R52) DPST N.O./N.O. CW Detent In-Line Term (R53) DPST N.O./N.O. CCW Detent In-Line Term (R54) DPST N.C./N.C. CW Detent In-Line Term (R55) DPST N.C./N.C. CCW Detent In-Line Term (R56) DPST N.O./N.C. CW Detent Horz Term (R57) DPST N.O./N.C. CCW Detent Horz Term (R58) DPST N.O./N.O. CW Detent Horz Term (R59) DPST N.O./N.O. CCW Detent Horz Term (R60) DPST N.C./N.C. CW Detent Horz Term (R61) DPST N.C./N.C. CCW Detent Horz Term (R70) DPDT CW Detent In-Line Term (R71) DPDT CCW Detent In-Line Term (R72) DPDT CW Detent Horz Term (R73) DPDT CCW Detent Horz Term APPLICABLE MODELS Models 91 Thru 96 Only All Models, 2nd Section is a Switch in Model 99 BUSHING A Metal Plain 3/8 (9.53 mm) D x 3/8 (9.53 mm) L C Metal Plain 1/4 (6.35 mm) D x 1/4 (6.35 mm) L D Plastic Unthreaded 3/8 " (9.53 mm) D x 3/8 " (9.53 mm) L R Metal Plain 10 mm D x 9 mm L U Metal Plain 7 mm D x 9 mm L 91 92 93 94 95 96 97 99 MODEL Single-Turn, In-Line PC Pins Single-Turn, In-Line J-Hooks Single-Turn, L-Pattern PC Pins Single-Turn, L-Pattern J-Hooks Single-Turn, Triangle-Pattern Solder Lugs Single-Turn, In-Line PC Pins, Sealed Single-Turn, L-Pattern PC Pins w/Switch Single-Turn, Triangle-Pattern Solder Lugs w/Switch SHAFT AVAILABLE LENGTH ONLY IN (FMS) BUSHING Code Description Code 16 1/2 "L A, C, D 20 5/8 "L A, C, D 24 3/4 L A, C, D 28 7/8 L A, D 32 1 "L A, D METRIC 12 12 mmL U 16 16 mmL R, U 19 19 mmL R 22 22 mmL R, U ELEMENT TYPE TAPER/TOLERANCE (A) Linear Cermet -10 % (H) Linear Cermet 5 % (B) (E) AVAILABLE ONLY IN LENGTHS BUSHINGS (CODE) (CODE) Single Slotted 1/4 (6.35 mm) D 16,20,24,28 A, D Single Flatted 1/4 (6.35 mm) D 24,28 A, D Single Plain 1/8 (3.18 mm) D 16,20,24 C Single Slotted 6 mm D Metric 16,19,22 R Single Slotted 4 mm D Metric 16,19,22 U Single Knurled 1/4 " (6.35 mm) D 32 A, D SHAFT TYPE B C D R T W (C) (D) (F) (G) (S) (T) RESISTANCE CODE VALUE IN OHMS (05) - 100 (30) - 15 K (28) -150 (16) - 20 K (06) - 200 (17) - 25 K (07) - 250 (18) - 50 K (08) - 500 (19) - 75 K (09) - 750 (20) - 100 K (10) - 1 K (31) - 150 K (29) - 1.5 K (21) - 200 K (11) - 2 K (22) - 250 K (12) - 2.5 K (23) - 500 K (13) - 5 K (24) - 750 K (14) - 7.5 K (25) - 1 M (15) - 10 K Linear C-P -20 % (10) - 1 K (18) - 50 K Linear C-P 10 % (12) - 2.5 K (20) - 100 K (13) - 5 K (22) - 250 K (15) - 10 K (23) - 500 K (16) - 20 K (25) - 1 M (17) - 25 K CW Audio Cermet 10 % (10) - 1 K (18) - 50 K CW Audio C-P 20 % (12) - 2.5 K (20) - 100 K CCW Audio Cermet 10 % (13) - 5 K (22) - 250 K CCW Audio C-P 20 % (15) - 10 K (23) - 500 K CW Audio C-P 10 % (17) - 25 K (25) - 1 M CCW Audio C-P 10 % Boldface features are Bourns standard options. All others are available with higher minimum order quantities. REV. 06/06 Specifications are subject to change without notice. Customers should verify actual device performance in their specific applications.