INCH-POUND MIL-PRF-39016/16G 3 December 2004 SUPERSEDING MIL-PRF-39016/16F 20 July 1988 PERFORMANCE SPECIFICATION SHEET RELAYS, ELECTROMAGNETIC, ESTABLISHED RELIABILITY, DPDT, LOW LEVEL TO 1.0 AMPERE (SENSITIVE, 60 MILLIWATTS) WITH INTERNAL DIODE FOR COIL TRANSIENT SUPPRESSION 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 are for reference only. Numbers do not appear on relay. 5. Relays shall have a plus (+) sign placed on the circuit diagram as shown. 6. Coil symbol optional in accordance with MIL-STD-1285. 7. Circuit diagram shown on part is the terminal view. FIGURE 1. Dimensions and configuration. AMSC N/A 1 of 10 FSC 5945 MIL-PRF-39016/16G 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 be certified to A-A-55485, A-55485/05-003, or A-55485/05-013. 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. Terminal numbers shown above for reference only. Numbers do not appear on relay. 8. Relays shall have a (+) sign placed on circuit diagram as shown. 9. Coil symbol optional in accordance with MIL-STD-1285. 10. Circuit diagram shown on part is the terminal view. FIGURE 2. Dimensions and configuration relay with spreader mounting pad attached. 2 MIL-PRF-39016/16G 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 life: 33 ohms maximum. After life: 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-39016/16G COIL DATA: See table I. Operate time: 4.0 ms maximum over temperature range with rated coil voltage. Release time: 7.5 ms maximum over temperature range from rated coil voltage. ELECTRICAL DATA: Insulation resistance: 1/ 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: 1/ 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) 500 500 500 500 500 500 500 500 N/A 375 500 N/A Altitude V rms (60 Hz) 125 All terminals to case DIODE CHARACTERISTICS: 2/ Maximum negative transient: 1.0 volt. Coil transient suppression: Applicable. Semiconductor in process screening: Applicable, visual inspection of semiconductors shall be in accordance with MIL-STD-750, methods 2073 or 2074. 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). 1/ Insulation resistance and dielectric withstanding voltage tests must always precede all other specified electrical measurements. Connect all coil terminals together to avoid damage to diodes. 2/ Warning: Reverse polarity on coil terminals will destroy diode. 4 MIL-PRF-39016/16G 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 method 1041, MIL-STD-750. PHYSICAL DATA: Terminal strength: method 211, MIL-STD-202. Pull test: Test condition A, 1 pound pull. Bend test: Test condition C, 1/2 pound load. Terminal twist test: As specified in MIL-PRF-39016. Solderability: Applicable. Dimensions and configuration: See figures 1 and 2. Weight: 4.25 grams (0.15 ounce) maximum, 4.50 grams (0.159 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): M39016/16- (dash number from table I and suffix letter, designating failure rate level). QUALIFICATION INSPECTION: Qualification inspection and sample size: See table I. 5 TABLE I. Dash numbers and characteristics. 1/ Dash number 2/ Lead length 1.500 min 3/ Lead length .187 .010 Lead length .500 min Spreader mounting pads (fig. 2) 4/ 017 018 019 020 021 022 023 024 025 026 027 028 029 030 031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048 Rated 5.0 6.0 12 26.5 36 48 9 18 Max 7.5 10 20 40 57 75 15 30 Coil resistance ohms 10% 100 200 850 3,300 6,500 11,000 400 1,600 Over temperature range SpeciSpeciSpeciSpeci- Specified fied fied fied fied pickup hold dropout pickup hold value value value value value (voltage) (voltage) (voltage) (voltage) (voltage) (V dc) (V dc) (V dc) (V dc) (V dc) 2.6 1.4 0.23 3.5 2.5 3.4 2.0 0.28 4.5 3.2 7.0 4.0 0.64 9.0 6.5 14.0 8.0 1.4 18 13 20 10 1.8 27 19 25.8 13 2.4 36 26 4.85 3.0 0.55 6.8 4.9 9.8 6.0 0.92 13.5 10 Specified dropout value (voltage) (V dc) 0.12 0.18 0.41 0.89 1.25 1.60 .35 0.59 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 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 - - - - - - -24R. 3/ 1.500 leads are inactive for new design. 4/ Relays supplied with spreader mounting pads (-041 through -048) shall have the spreader mounting pad rigidly attached. 5/ CAUTION: The use of any coil voltage less than the rated coil voltage will compromise the operation of the relay. MIL-PRF-39016/16G 6 . At 25C Coil voltage (V dc) 5/ MIL-PRF-39016/16G 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 M39016/16-036 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 M39016/16-033 2 units each PIN M39016/16-034 Qualification inspection, M39016/16-035 Q1. M39016/16-037 M39016/16-038 M39016/16-039 M39016/16-040 1/ For retention of qualification or extension of qualification to lower failure rate levels, all life test data accumulated on MIL-PRF-39016/21 may be used in addition to MIL-PRF39016/16 data. Prior to performance of qualification or extension 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-PRF-39016, if the relay manufacturer elects to test the number of units permitting one or more failures. Prior to performance of qualification inspection testing the relay manufacturer shall preselect the sample size. 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, solderability, seal, visual and mechanical inspection (external). 7 MIL-PRF-39016/16G Qualification inspection (reduced testing for previously qualified relays) for relays supplied with spreader mounting pads (-041 through -048), two (2) 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, 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. Qualification inspection (reduced testing) and sample size: See table III. If the relays produced for MIL-PRF-39016/16 are similar in construction and design except for the steering diode to the relays produced for MIL-PRF-39016/21, then reduced testing for qualification of MIL-PRF-39016/16 relays may be performed concurrent with or subsequent to successful qualification of MIL-PRF-39016/21. TABLE III. Qualification inspection (reduced testing). Examination or test 2 units each coil voltage - Q1 of qualification inspection table 1 unsealed sample unit for internal examination. SUPERSESSION DATA: Supersession data: See table IV. 8 MIL-PRF-39016/16G TABLE IV. Supersession data. 1/ Superseded New Superseded New Superseded New part no. part no. part no. part no. part no. part no. M5757/101- M39016/16M39016/16- M39016/16M39016/16- M39016/162/ 2/ 2/ 001 017 001 017 011 027 002 018 002 018 012 028 003 019 003 019 013 029 004 020 004 020 014 030 005 021 005 021 015 031 006 022 006 022 016 032 007 025 007 023 008 026 008 024 009 027 009 025 010 028 010 026 011 029 012 030 1/ Dash numbers -017 through -024, are inactive for new design and are for support of existing equipment 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. TABLE V. Cross reference for Government logistical support. Superseded New part no. part no. M5757/101- M39016/16- Support with part no. M39016/ 1/ 16-017 16-018 21-010 21-012 21-029 21-030 16-025 16-026 21-022 21-024 21-031 21-032 Superseded New part no. part no. M39016/16- M39016/16- Support New Support with part no. with part no. M39016/16part no. M39016/ 1/ M39016/ 1/ 001 017 001 017 16-017 033 16-033 002 018 002 018 16-018 034 16-034 003 019 003 019 21-010 035 21-036 004 020 004 020 21-012 036 21-038 005 021 005 021 21-039 037 21-039 006 022 006 022 21-030 038 21-040 007 025 007 023 21-009 039 21-035 008 026 008 024 21-011 040 21-037 009 027 009 025 21-033 041 16-041 010 028 010 026 16-034 042 16-042 011 029 011 027 21-036 043 21-044 012 030 012 028 21-038 044 21-046 013 029 21-039 045 21-047 014 030 21-040 046 21-048 015 031 21-035 047 21-043 016 032 21-037 048 21-045 1/ Complete part number shall contain suffix letters 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. 9 MIL-PRF-39016/16G Referenced documents. In addition to MIL-PRF-39016, this document references the following: A-A-55485, /5 MIL-PRF-39016/21 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, MC, OS, SH Air Force - 19, 99 (Project 5945-1254) 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. 10