INCH-POUND MIL-PRF-39016/20J 3 December 2004 SUPERSEDING MIL-PRF-39016/20H 13 May 1987 PERFORMANCE SPECIFICATION SHEET RELAYS, ELECTROMAGNETIC, ESTABLISHED RELIABILITY, DPDT, LOW LEVEL TO 1.0 AMPERE WITH INTERNAL DIODES FOR COIL TRANSIENT SUPPRESSION AND POLARITY REVERSAL PROTECTION, 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 .100 .280 .335 .370 mm 0.03 0.05 0.08 0.43 0.79 0.89 2.54 7.11 8.51 9.40 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. Relays shall have a plus (+) sign placed on the circuit diagram as shown. 5. Coil symbol optional in accordance with MIL-STD-1285. 6. Circuit diagram shown on part is the terminal view. 7. The grounding pin shown is a noninsulated case ground applicable to -079 through -084 only. FIGURE 1. Dimensions and configuration (round). AMSC N/A 1 of 13 FSC 5945 MIL-PRF-39016/20J Inches .001 .002 .003 .017 .031 .035 .050 .200 .280 .315 .370 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. Relays shall have a plus (+) sign placed on the circuit diagram as shown. 5. Coil symbol optional in accordance with MIL-STD-1285. 6. Circuit diagram shown on part is the terminal view. 7. Shape optional within envelope dimension. 8. The grounding pin shown is a non-insulated case ground applicable to -085 through -090 only. FIGURE 2. Dimensions and configuration (square or round). 2 mm 0.03 0.05 0.08 0.43 0.79 0.89 1.27 5.08 7.11 8.00 9.40 MIL-PRF-39016/20J Inches .001 .002 .003 .005 .017 .031 .035 .078 .100 .148 .150 .300 .335 .390 .446 mm 0.03 0.05 0.08 0.13 0.43 0.79 0.89 1.98 2.54 3.76 3.81 7.62 8.51 9.91 11.33 NOTES: FIGURE 0. 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-55485/05-003, or A-55485/05-013. 5. Dimensions and tolerances 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. Relays shall have a plus (+) sign place on the circuit diagram as shown. 8. Coil symbol optional in accordance with MIL-STD-1285. 9. Circuit diagram shown on part is the terminal view. 10. The grounding pin shown is a non-insulated case ground applicable to -091 through -096 only. FIGURE 3. Dimensions and configuration relay with spreader mounting pad (.100 x .300terminal spacing) attached. 3 MIL-PRF-39016/20J Inches .001 .002 .003 .017 .031 .035 .078 .100 .148 .150 .300 .390 .446 mm 0.03 0.05 0.08 0.43 0.79 0.89 1.98 2.54 3.76 3.81 7.62 9.91 11.33 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, A55485/05-014. 5. Dimensions and tolerances 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. Relays shall have a plus (+) sign place on the circuit diagram as shown. 9. Circuit diagram shown on part is the terminal view. FIGURE 4. Dimensions and configuration relay with spreader mounting pad (.100 x .300terminal spacing) attached (square or round). 4 MIL-PRF-39016/20J 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 figure 3 spreader mounting pad attached and 0.150 ohm maximum with figure 4 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 figure 3 spreader mounting pad attached and 0.250 ohm maximum with figure 4 spreader mounting pad attached). Low level: During life: 33 ohms maximum. After life: 0.15 ohm maximum (0.175 ohm maximum with figure 3 spreader mounting pad attached and 0.200 ohm maximum with figure 4 spreader mounting pad attached). Intermediate current: During: 1 ohm maximum. After: 0.20 ohm maximum (0.225 ohm maximum with figure 3 spreader mounting pad attached and 0.250 ohm maximum with figure 4 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. 5 MIL-PRF-39016/20J COIL DATA: See table I. Operate time: 2.0 ms maximum over temperature range with rated coil voltage. Release time: 4.0 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: 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. Sea level V rms (60 Hz) 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 Coil transient suppression: Applicable. Diode block integrity (perform this test after coil transient suppression test in all inspection tables of MIL-PRF39016): With applicable voltage applied to the relay coil circuit in the reverse direction, monitor leakage current with dc microammeter, oscilloscope, or qualifying activity approved test equipment. Leakage current shall not exceed the specified value. Block integrity maximum leakage current: 1A at 50 V dc. Maximum negative transient: 1.0 volt. Breakdown voltage: 100 V dc minimum at 10 microamperes (A). (This test may be performed in-process or as final assembly). Semiconductor in-process screening: Applicable, visual inspection of semiconductors shall be in accordance with MIL-STD-750, method 2073 or 2074. ENVIRONMENTAL DATA: Temperature range: -65C to +125C. 6 MIL-PRF-39016/20J 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. PHYSICAL DATA: Terminals: 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 figure 1, 2, 3, and 4. Weight: 2.27 grams (0.08 ounce) maximum, 2.52 grams (0.089 ounce) maximum with spreader mounting pad. 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): M39016/20- (dash number from table I and suffix letter designating failure rate level). 7 TABLE I. Dash numbers and characteristics. 1/ Lead length .187 +.040 -.010 007 008 009 010 011 012 019 020 021 022 023 024 ------------------------- 037 038 039 040 041 042 043 044 045 046 047 048 ------------------------- Dash numbers 2/ Lead Spreader Lead Spreader length mounting length mounting .500 pads .500 mounting min 4/ min pads with with ground ground 4/ 049 --079 --050 --080 --051 --081 --052 --082 --053 --083 --054 --084 --055 --085 --056 --086 --057 --087 --058 --088 --059 --089 --060 --090 ----061 --091 --062 --092 --063 --093 --064 --094 --065 --095 --066 --096 --073 ------074 ------075 ------076 ------077 ------078 ----- See footnotes following page. Fig. 1 2 3 4 Coil voltage (V dc) 5/ Rated Max 5.0 6.0 9.0 12.0 18.0 26.5 5.0 6.0 9.0 12.0 18.0 26.5 5.0 6.0 9.0 12.0 18.0 26.5 5.0 6.0 9.0 12.0 18.0 26.5 5.8 8.0 12.0 16.0 24.0 32.0 5.8 8.0 12.0 16.0 24.0 32.0 5.8 8.0 12.0 16.0 24.0 32.0 5.8 8.0 12.0 16.0 24.0 32.0 Coil resistance (ref. only Ohms 39 78 220 390 880 1,560 39 78 220 390 880 1,560 39 78 220 390 880 1,560 39 78 220 390 880 1,560 At 25C Coil circuit Specicurrent (mA) fied 6/ 7/ pickup value (volt.) Max Min (V dc) 128.2 78.3 42.9 32.8 22.1 18.5 128.2 78.3 42.9 32.8 22.1 18.5 128.2 78.3 42.9 32.8 22.1 18.5 128.2 78.3 42.9 32.8 22.1 18.5 93.2 58.3 33.0 25.6 17.5 14.8 93.2 58.3 33.0 25.6 17.5 14.8 93.2 58.3 33.0 25.6 17.5 14.8 93.2 58.3 33.0 25.6 17.5 14.8 3.2 4.0 6.3 8.0 11.5 15.2 3.2 4.0 6.3 8.0 11.5 15.2 3.2 4.0 6.3 8.0 11.5 15.2 3.2 4.0 6.3 8.0 11.5 15.2 Specified hold value (volt.) (V dc) 2.3 2.8 4.2 5.2 7.3 9.5 2.3 2.8 4.2 5.2 7.3 9.5 2.3 2.8 4.2 5.2 7.3 9.5 2.3 2.8 4.2 5.2 7.3 9.5 Specified dropout value (volt.) (V dc) 0.6 0.7 0.9 1.1 1.4 1.8 0.6 0.7 0.9 1.1 1.4 1.8 0.6 0.7 0.9 1.1 1.4 1.8 0.6 0.7 0.9 1.1 1.4 1.8 Over temperature range Speci- Speci- Specified fied fied droppickup hold value value out (volt.) (volt.) value (V dc) (V dc) (volt.) (V dc) 4.0 2.8 0.6 5.0 3.4 0.7 7.8 5.3 0.8 10.0 6.5 0.9 14.5 10.0 1.1 19.0 13.0 1.4 4.0 2.8 0.6 5.0 3.4 0.7 7.8 5.3 0.8 10.0 6.5 0.9 14.5 10.0 1.1 19.0 13.0 1.4 4.0 2.8 0.6 5.0 3.4 0.7 7.8 5.3 0.8 10.0 6.5 0.9 14.5 10.0 1.1 19.0 13.0 1.4 4.0 2.8 0.6 5.0 3.4 0.7 7.8 5.3 0.8 10.0 6.5 0.9 14.5 10.0 1.1 19.0 13.0 1.4 MIL-PRF-39016/20J 8 Lead length 1.500 min 3/ MIL-PRF-39016/20H 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, 007L - - - - - -66R. 3/ 1.500 leads are inactive for new design. 4/ Relays supplied with spreader mounting pads (-061 through -066 and -091 through -096) 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. 6/ Coil resistance not directly measurable at relay terminals. When rated voltage is applied to the coil terminals, the coil circuit current must be within the limits shown. Measure at 25C at nominal voltage for 5 seconds, maximum. 7/ Delete "Coil resistance" and substitute "Coil current" test in all inspection tables of MIL-PRF-39016. 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 M39016/20-054 18 units plus 1 open unit for or level L at C = 0 2/ M39016/20-060 33 units plus 1 open unit for level M at C = 0 2/ Qualification inspection as applicable M39016/20-049 2 units each PIN M39016/20-050 Qualification inspection, M39016/20-051 Q1. M39016/20-052 M39016/20-053 M39016/20-084 1 unit terminal strength and or solderability. M39016/20-055 M39016/20-056 M39016/20-057 M39016/20-058 M39016/20-059 M39016/20-090 1 unit terminal strength and solderability. 1/ For 1 only: 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 MILPRF-39016/20 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-PRF-39016, if the relay manufacturer 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. 9 MIL-PRF-39016/20J Initial qualification of relays supplied with spreader mounting pads (-061 through -066 and -073 through -078 and 091 through -096), 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 and dropout values (voltage), 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 (-061 through -066, -073 through -078, and -091 through -096), two units from figure 3 and two units from figure 4 of the 26.5 volt rated coil voltage (-066 and -078) 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-39106 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 spread mounting pads (-061 through -066, -073 through -078, and -091 through -096) shall be tested as specified below: Perform seal test immediately, preceding the A2 electrical tests. Relay leads shall be formed and the mounting pad removed before the seal test. After the seal test, the 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. 10 MIL-PRF-39016/20J Figure 1 only: If the relays produced for MIL-PRF-39016/20 are similar in construction and design except for the coils to the relays produced for MIL-PRF-39016/21, then reduced testing for qualification of MIL-PRF-39016/20 relays may be performed concurrent with or subsequent to successful qualification of MIL-PRF-39016/21 relays. 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. TABLE IV. Supersession data. 1/ Superseded part no. M39016/20001 002 003 004 005 006 013 014 015 016 017 018 New part no. M39016/20007 008 009 010 011 012 019 020 021 022 023 024 Superseded part no. M39016/20025 026 027 028 029 030 031 032 033 034 035 036 New part no. M39016/20037 038 039 040 041 042 043 044 045 046 047 048 Superseded part no. M39016/20067 068 069 070 071 072 New part no. M39016/20061 062 063 064 065 066 1/ Dash numbers -001 through -006, -013 through -018, and -025 through -036 are inactive for new design and are for support of existing equipment designs only. Cross reference for Government logistical support: See table V. 11 MIL-PRF-39016/20J TABLE V. Cross reference for Government logistical support. Superseded part no. M39016/20001 002 003 004 005 006 013 014 015 016 017 018 025 026 027 028 029 030 031 032 033 034 035 036 067 068 069 070 071 072 New part no. M39016/20007 008 009 010 011 012 019 020 021 022 023 024 037 038 039 040 041 042 043 044 045 046 047 048 061 062 063 064 065 066 Support with part no. M39016/20007 008 009 010 011 012 007 008 009 010 011 012 049 050 051 052 053 054 049 050 051 052 053 054 061 062 063 064 065 066 New part no. M39016/20049 050 051 052 053 054 055 056 057 058 059 060 061 062 063 064 065 066 073 074 075 076 077 077 078 079 080 081 082 083 084 Support with part no. M39016/20049 050 051 052 053 054 049 050 051 052 053 054 061 062 063 064 065 066 073 074 075 076 077 078 078 079 080 081 082 083 084 New part no. M39016/20085 086 087 088 089 090 091 092 093 094 095 096 Support with part no. M39016/20085 086 087 088 089 090 091 092 093 094 095 096 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. 12 MIL-PRF-39016/20J 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 - 99 (Project 5945-1255) 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. 13