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Supersedes data of 17th November 1998 File under BCcomponents, BC08
2000 Oct 20
Cemented wirewound resistors
2000 Oct 20 2
BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20
FEATURES
- High power dissipation in small volume
- High pulse load handling capabilities.
APPLICATIONS
- Ballast switching
- Shunt in small electric motors
- Power supplies.
DESCRIPTION
The resistor element is a resistive wire which is wound in a single layer on a ceramic rod. Metal caps are pressed over the ends of the rod. The ends of the resistance wire and the leads are connected to the caps by welding. Tinned copper-clad iron leads with poor heat conductivity are employed permitting the use of relatively short leads to obtain stable mounting without overheating the solder joint. The resistor is coated with a green silicon cement which is not resistant to aggressive fluxes. The coating is non-flammable, will not drip even at high overloads and is resistant to most commonly used cleaning solvents, in accordance with “MIL-STD-202E, method 215” and “IEC 60068-2-45”. QUICK REFERENCE DATA AC01 AC03 AC04 AC05 AC07 AC10 AC15 AC20 Resistance range 0.1 Ω = to 2.4 kΩ = 0.1 Ω to 5.1 kΩ 0.1 Ω to 6.8 kΩ 0.1 Ω to 10 kΩ 0.1 Ω to 15 kΩ 0.68 Ω to 27 kΩ 0.82 Ω to 39 kΩ 1.2 Ω to 56 kΩ Resistance tolerance ±5%; E24 series Maximum permissible body temperature 350 °C Rated dissipation at Tamb =4 0 °C 1 W3 W4 W5 W7 W 1 0 W 1 5 W 2 0 W Climatic category (IEC 60068) 40/200/56 Basic specification IEC 60115-1 Stability after: load, 1000 hours ∆ R/R max.: ±5% + 0.1 Ω climatic tests ∆R/R max.: ±1% + 0.05 Ω short time overload ∆ R/R max.: ±2% + 0.1 Ω
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20
ORDERING INFORMATION
Table 1 Ordering code indicating resistor type and packaging Notes 1. Products with bent leads and loose in box, are available on request. 2. Last 3 digits available on request. TY PE LOOSE IN BOX BANDOLIER IN AMMOPACK STRAIGHT LEADS RADIAL STRAIGHT LEADS 100 units 2500 units 500 units 1000 units AC01 Ordering code (12NC)
- The resistors have a 12-digit ordering code starting with 23
- The subsequent 7 digits indicate the resistor type and packaging; see Table 1.
- The remaining 3 digits indicate the resistance value: – The first 2 digits indicate the resistance value. – The last digit indicates the resistance decade in accordance with Table 2. Table 2 Last digit of 12NC RESISTANCE DECADE LAST DIGIT 0 . 1t o0 . 9 1 Ω 7 1t o9 . 1Ω 8 10 to 91 Ω 9 1 0 0t o9 1 0Ω 1 1t o9 . 1kΩ 2 10 to 56 kΩ 3 ORDERING EXAMPLE The ordering code of an AC01 resistor, value 47 Ω , supplied in ammopack of 1000 units is: 2306 328 33479. Product specifications deviating from the standard values are available on request.
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 FUNCTIONAL DESCRIPTION Product characterization Standard values of nominal resistance are taken from the E24 series for resistors with a tolerance of ±5%. The values of the E24 series are in accordance with “IEC publication 60063 ”. Limiting values Note 1. The maximum voltage that may be continuously applied to the resistor element, see “IEC publication 60266 ”. The maximum permissible hot-spot temperature is 350 °C. DERATING The power that the resistor can dissipate depends on the operating temperature; see Fig.1. TYP E LIMITING VOLTAGE(1) (V) LIMITING POWER (W) Tamb =4 0 °CT amb =7 0 °C AC01 1 0.9 AC03 3 2.5 AC04 4 3.5 AC05 5 4.7 AC07 7 5.8 AC10 10 8.4 AC15 15 12.5 AC20 20 16.0 VP n R×= Fig.1 Maximum dissipation (Pmax) as a function of the ambient temperature (T amb). 40 0 40 70 200 100 Pmax (%) T ( C)amb o MRA574
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 PULSE LOADING CAPABILITIES How to generate the maximum allowed pulse-load from the graphs composed for wirewound resistors of the AC-types. Single pulse condition; see Fig.3 1. If the applied pulse energy in Joules or Wattseconds is known and also the R-value to be used in the application; take the R-value on the X-axis and go vertically to the curved line. From this point go horizontally to the Y-axis, this point gives the maimum allowed pulse energy in Joules/ohm or Wattsec./ohm. By multiplying this figure with -value in use gives the maximum allowed pulse-energy in Joules or Wattsec. If this figure is higher than the applied pulse-energy the application is allowed. Otherwise take one of the other graphs belonging to AC-types with higher P 2. If, contrary to the information above, the applied peak-voltage and impulse times ti are known. Calculate the pulse-energy (Ep) in Joules or Wattsec. by the use of the following formula: (Vp = peak voltage; ti =i m p u l s e - t i m e ) By dividing this result with the Rn-value of the R in use, gives the value Wattsec./ohm on the Y-axis. Draw a line horizontally to the curved line and at the intersection the vertical line to the X-axis gives the maximum allowed R n-value to be used in the application. If this Rn-value is higher than the R-value to be used in the application, the application is allowed. If not, take one of the other graphs belonging to AC-types with higher Pn or change the Rn-value to be used. Repetitive pulse condition; see Fig.2 With these graphs we can determine the allowed pulse-energy in Watts depending on the impulse- time ti and the repetition time tp of the pulses. The parameter is the Resistance Value. If the pulse shape is known (impulse-time ti and repetition time tp), draw a line vertically from the X-axis at the mentioned ti to the line of the involved R-value. From the intersection the horizontal line to the Y- axis indicates the maximum allowed pulse-load at a certain tp/ti. If the vertical line from the X-axis crosses the applied t p/ti before reaching the R-line, this tp/ti line gives the maximum allowed pulse-energy at the Y-axis. If the applied pulse-energy is known (in Watts) and the impulse-time t i also, draw a line horizontally from the Y-axis to the crossing with the pulse-line (ti) and find the possible R-value needed in this application. The horizontal t p/ti lines give the maximum allowed pulse-load till they reach the R-line, that point indicates the maximum allowed impulse-time ti at the horizontal axis. Ep Vp 2
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 Fig.2 Pulse on a regular basis; maximum permissible peak pulse power as a function of pulse duration (ti). Pˆmax() AC01 CCB370 10−110−210−310−4 10−1 102 103 104 Pmax (W) ti (s) tp/ti = 1000 tp/ti = 200 tp/ti = 50 tp/ti = 10 tp/ti = 2 ˆ 0.1 Ω 1 Ω 10 Ω 100 Ω 2 kΩ Fig.3 Pulse capability; Ws as a function of Rn. AC01 103 10410210110−1 CCB371 102 10−4 10−1 10−2 10−3 pulse energy (Ws/Ω) R n (Ω )
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 Fig.4 Pulse on a regular basis; maximum permissible peak pulse voltage as a function of pulse duration (ti). Vˆmax() AC01 1500 500 10−6 10−5 10−4 10−3 10−2 10−1 1 CCB372 1000 ti (s) Vmax (V) ˆ Fig.5 Pulse on a regular basis; maximum permissible peak pulse power as a function of pulse duration (ti). Pˆmax() AC03 CCB373 10−110−210−310−4 10−1 102 103 104 Pmax (W) ti (s) ˆ tp/ti = 1000 tp/ti = 200 tp/ti = 50 tp/ti = 10 tp/ti = 2 0.1 Ω 1 Ω 10 Ω 110 Ω4.7 kΩ
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 Fig.6 Pulse capability; Ws as a function of Rn. AC03 103 10410210110−1 CCB374 103 102 10−4 10−1 10−2 10−3 R n (Ω ) pulse energy (Ws/Ω) Fig.7 Pulse on a regular basis; maximum permissible peak pulse voltage as a function of pulse duration (ti). Vˆmax() AC03 2000 1500 500 10−6 10−5 10−4 10−3 10−2 10−1 1 CCB375 1000 ti (s) Vmax (V) ˆ
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 Fig.8 Pulse on a regular basis; maximum permissible peak pulse power as a function of pulse duration (ti). Pˆmax() AC04 CCB376 10−110−210−310−4 10−1 102 103 104 Pmax (W) ti (s) ˆ tp/ti = 1000 tp/ti = 200 tp/ti = 50 tp/ti = 10 tp/ti = 2 0.1 Ω 1 Ω 10 Ω 100 Ω 6.8 kΩ Fig.9 Pulse capability; Ws as a function of Rn. AC04 103 10410210110−1 CCB377 103 102 10−4 10−1 10−2 10−3 R n (Ω ) pulse energy (Ws/Ω)
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 Fig.10 Pulse on a regular basis; maximum permissible peak pulse voltage as a function of pulse duration (ti). Vˆmax() AC04 2500 2000 1500 500 10−6 10−5 10−4 10−3 10−2 10−1 1 CCB378 1000 ti (s) Vmax (V) ˆ Fig.11 Pulse on a regular basis; maximum permissible peak pulse power as a function of pulse duration (t i). Pˆmax() AC05 CCB379 10−110−210−310−4 10−1 102 103 104 Pmax (W) ti (s) ˆ tp/ti = 1000 tp/ti = 200 tp/ti = 50 tp/ti = 10 tp/ti = 2 0.1 Ω 1.1 Ω 11 Ω 100 Ω 8.2 kΩ
2000 Oct 20 11
BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 Fig.12 Pulse capability; Ws as a function of Rn. AC05 103 10410210110−1 CCB380 103 102 10−4 10−1 10−2 10−3 R n (Ω ) pulse energy (Ws/Ω) Fig.13 Pulse on a regular basis; maximum permissible peak pulse voltage as a function of pulse duration (ti). Vˆmax() AC05 2500 2000 1500 500 10−6 10−5 10−4 10−3 10−2 10−1 1 CCB381 1000 ti (s) Vmax (V) ˆ
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 Fig.14 Pulse on a regular basis; maximum permissible peak pulse power as a function of pulse duration (ti). Pˆmax() AC07 CCB382 10−110−210−310−4 102 103 104 Pmax (W) ti (s) tp/ti = 1000 tp/ti = 200 tp/ti = 50 tp/ti = 10 tp/ti = 2 0.1 Ω 1 Ω 11 Ω 100 Ω 15 kΩ Fig.15 Pulse capability; Ws as a function of Rn. AC07 103 10510410210110−1 CCB383 103 102 10−4 10−1 10−2 10−3 R n (Ω ) pulse energy (Ws/Ω)
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 Fig.16 Pulse on a regular basis; maximum permissible peak pulse voltage as a function of pulse duration (ti). Vˆmax() AC07 5000 4000 3000 1000 10−6 10−5 10−4 10−3 10−2 10−1 1 CCB384 2000 ti (s) Vmax (V) ˆ Fig.17 Pulse on a regular basis; maximum permissible peak pulse power as a function of pulse duration (ti). Pˆmax() AC10 CCB385 10−110−210−310−4 102 103 105 104 ti (s) Pmax (W) ˆ tp/ti = 1000 tp/ti = 200 tp/ti = 50 tp/ti = 10 tp/ti = 2 0.22 Ω 2.2 Ω 33 Ω 240 Ω 15 kΩ
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 Fig.18 Pulse capability; Ws as a function of Rn. AC10 103 10510410210110−1 CCB386 103 102 10−4 10−1 10−2 10−3 R n (Ω ) pulse energy (Ws/Ω) Fig.19 Pulse on a regular basis; maximum permissible peak pulse voltage as a function of pulse duration (ti). Vˆmax() AC10 5000 4000 3000 1000 10−6 10−5 10−4 10−3 10−2 10−1 1 CCB387 2000 ti (s) Vmax (V) ˆ
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 Fig.20 Pulse on a regular basis; maximum permissible peak pulse power as a function of pulse duration (ti). Pˆmax() AC15 CCB388 10−110−210−310−4 102 103 105 104 ti (s) Pmax (W) ˆ tp/ti = 1000 tp/ti = 200 tp/ti = 50 tp/ti = 10 tp/ti = 2 0.33 Ω 4.3 Ω 33 Ω 330 Ω 39 kΩ Fig.21 Pulse capability; Ws as a function of Rn. AC15 103 10510410210110−1 CCB389 103 102 10−4 10−1 10−2 10−3 R n (Ω ) pulse energy (Ws/Ω)
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 Fig.22 Pulse on a regular basis; maximum permissible peak pulse voltage as a function of pulse duration (ti). Vˆmax() AC15 7000 6000 5000 4000 3000 1000 CCB390 2000 ti (s) Vmax (V) ˆ Fig.23 Pulse on a regular basis; maximum permissible peak pulse power as a function of pulse duration (ti). Pˆmax() AC20 CCB391 10−110−210−310−4 102 103 105 104 ti (s) Pmax (W) ˆ tp/ti = 1000 tp/ti = 200 tp/ti = 50 tp/ti = 10 tp/ti = 2 0.47 Ω 5.1 Ω 47 Ω 470 Ω 56 kΩ
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 Fig.24 Pulse capability; Ws as a function of Rn. AC20 103 10510410210110−1 CCB392 103 102 10−4 10−1 10−2 10−3 R n (Ω ) pulse energy (Ws/Ω) Fig.25 Pulse on a regular basis; maximum permissible peak pulse voltage as a function of pulse duration (ti). Vˆmax() AC20 10000 8000 6000 2000 10−6 10−5 10−4 10−3 10−2 10−1 1 CCB393 4000 ti (s) Vmax (V) ˆ
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20
Application information
Fig.26 Temperature rise of the resistor body as a function of the dissipation. MGB730 2420 350 300 250 200 150 100 0 4 12 16 ∆T at hot spot (K) P (W) AC01 AC03 AC04 AC05 AC07 AC10 AC15 AC20 Fig.27 Lead length as a function of the dissipation with the temperature rise at the end of the lead (soldering spot) as a parameter. P (W) lead length (mm) MRA573
20 K 30 K∆T = 10 K
Fig.28 Lead length as a function of the dissipation with the temperature rise at the end of the lead (soldering spot) as a parameter. 123 MGB731 P (W) lead length (mm) 60 K 70 K
50 K∆T = 40 K
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 Fig.29 Lead length as a function of the dissipation with the temperature rise at the end of the lead (soldering spot) as a parameter. 12 4 MGB732 P (W) lead length (mm)
50 K∆T = 40 K 60 K
Fig.30 Lead length as a function of the dissipation with the temperature rise at the end of the lead (soldering spot) as a parameter. MGB733
234 P (W)
(mm)
50 K∆T = 40 K 60 K 70 K
Fig.31 Lead length as a function of the dissipation with the temperature rise at the end of the lead (soldering spot) as a parameter. 24 8 MGB734 P (W) lead length (mm) ∆T = 40 K 80 K 90 K
50 K 60 K 70 K
Fig.32 Lead length as a function of the dissipation with the temperature rise at the end of the lead (soldering spot) as a parameter. AC10 05 1 0 MGB735 P (W) lead length (mm) 50 K 60 K 70 K 80 K ∆T = 40 K
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 Fig.33 Lead length as a function of the dissipation with the temperature rise at the end of the lead (soldering spot) as a parameter. 05 1 0 MGB736 P (W) lead length (mm)
50 K 60 K 70 K∆T = 40 K
Fig.34 Lead length as a function of the dissipation with the temperature rise at the end of the lead (soldering spot) as a parameter. 05 1 0 MGB737
15 P (W)
(mm) The resistor is suitable for processing on cutting and bending machines. Ensure that the temperature rise of the resistor body does not affect nearby components or materials by conducted or convected heat. Figure 26 shows the hot-spot temperature rise of the resistor body as a function of dissipated power. Figures 27 to 34 show the lead length as a function of dissipated power and temperature rise.
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 MECHANICAL DATA Mass per 100 units Marking The resistor is marked with the nominal resistance value, the tolerance on the resistance and the rated dissipation at T amb =4 0 °C. For values up to 910Ω , the R is used as the decimal point. For values of 1 kΩ and upwards, the letter K is used as the decimal point for the k Ω indication. TYPE MASS (g) AC01 55 AC03 110 AC04 140 AC05 220 AC07 300 AC10 530 AC15 840 AC20 1090 Outlines Table 3 Resistor type and relevant physical dimensions; see Figs 35 and 36 TY PE ∅ D MAX. (mm) L MAX. (mm) ∅ d (mm) b (mm) h (mm) P (mm) S MAX. (mm) ∅ B MAX. (mm) AC01 4.3 10 0.8 ±0.03 AC03 5.5 13 1.3 8 10e 21 . 2AC04 5.7 17 AC05 7.5 17 AC07 7.5 25 13e AC10 8 44 Fig.35 Type with straight leads. d L DO O MRA571For dimensions see Table 3. MLB677P 5 1 BO h 2 Fig.36 Type with cropped and formed leads. Dimensions in mm. For dimensions see Table 3. Available on request for types: AC03, AC04, AC05 and AC07. DO MLB676 L P 4 P 0.5 2 min b S 0.1 dO MAINTE NANCE TYPE
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 Fig.37 Type with double kink. Dimensions in mm. For dimensions see Table 4. ∅ 0.8 to 1.4. JW2 9 ∅ DP1 ±0.5 P2 ±3 S ∅ B ±0.07 ∅ d b1 4.5 +1 h + 2 Lmax (1) P1 ±0.5 Table 4 Resistor type and relevant physical dimensions; see Fig.37 TYPE LEAD STYLE ∅ D (mm) L MAX. (mm) (mm) (mm) h (mm) (mm) (mm) S MAX. (mm) ∅ B (mm) AC03 AC04 AC05 double kink large pitch 0.8 ±0.03 10 1.30 +0.25/-0.20 1.65 +0.25/-0.20 82 5 . 4 2 5 . 42 1 . 0 AC03 AC04 AC05 double kink small pitch 0.8 ±0.03 10 1.30 +0.25/-0.20 2.15 +0.25/-0.20 82 2 . 0 2 0 . 02 1 . 0
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 TESTS AND REQUIREMENTS Essentially all tests are carried out in accordance with the schedule of “IEC publications 60115-1 and 60115-4 ”, category 40/200/56 (rated temperature range −40 °Ct o +200 °C; damp heat, long term, 56 days). The testing also covers the requirements specified by EIA and EIAJ. The tests are carried out in accordance with IEC publication 60068, “Recommended basic climatic and mechanical robustness testing procedure for electronic components ” and under standard atmospheric conditions according to “IEC 60068-1”, subclause 5.3. In Table 5 the tests and requirements are listed with reference to the relevant clauses of “IEC publications 60115-1, 115-4 and 68 ”; a short description of the test procedure is also given. In some instances deviations from the IEC recommendations were necessary for our method of specifying. All soldering tests are performed with mildly activated flux. Table 5 Test procedures and requirements IEC 60115-1 CLAUSE IEC 60068 TEST METHOD TEST PROCEDURE REQUIREMENTS Tests in accordance with the schedule of IEC publication 60115-1 4.15 robustness of resistor body load 200 ±10 N no visible damage
4.16 U robustness of
terminations: Ua tensile all samples load 10 N; 10 s Ub bending half number of samples load 5 N 90 °, 180°, 90° Uc torsion other half of samples 2 × 180° in opposite directions no visible damage
4.17 Ta solderability 2 s; 235 °C; flux 600 good tinning; no damage
4.18 Tb resistance to soldering
thermal shock: 3 s; 350 °C; 2.5 mm from body 4.19 14 (Na) rapid change of temperature 30 minutes at −40 °C and 30 minutes at +200 °C; 5 cycles no visible damage ∆R/R max.: ±1% + 0.05 Ω
4.22 Fc vibration frequency 10 to 500 Hz; displacement
0.75 mm or acceleration 10 g; 3 directions; total 6 hours (3 × 2 hours) no damage
4.20 Eb bump 4000 ±10 bumps; 390 m/s2 no damage
R = 6 mm load MBB179
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BCcomponents Product specification Cemented wirewound resistors AC01/03/04/05/07/10/15/20 4.23 climatic sequence:
4.23.2 Ba dry heat 16 hours; 200 °C
4.23.3 Db damp heat
(accelerated) st cycle 24 hours; 55 °C; 95 to 100% RH
4.23.4 Aa cold 2 hours; −40 °C
4.23.5 M low air pressure 1 hour; 8.5 kPa; 15 to 35 °C
4.23.6 Db damp heat
(accelerated) remaining cycles 5 days; 55 °C; 95 to 100% RH ∆R/R max.: ±1% + 0.05 Ω 4.24.2 3 (Ca) damp heat (steady state) 56 days; 40 °C; 90 to 95% RH; dissipation ≤0.01 Pn no visible damage ∆R/R max.: ±1% + 0.05 Ω 4.8.4.2 temperature coefficient R<1 0 Ω TC ≤± 600 × 10−6/K TC ≤ +140 × 10−6/K temperature rise horizontally mounted, loaded with P n hot-spot temperature less than maximum body temperature 4.13 short time overload room temperature; dissipation 10 × Pn; 5 s (voltage not more than
1000 V/25 mm)
∆R/R max.: ±2% + 0.1 Ω 4.25.1 endurance (at 40 °C) 1000 hours loaded with P n; 1.5 hours on and 0.5 hours off no visible damage ∆R/R max.: ±5% + 0.1 Ω 4.25.1 endurance (at 70 °C) 1000 hours loaded with 0.9P n; 1.5 hours on and 0.5 hours off no visible damage ∆R/R max.: ±5% + 0.1 Ω 4.23.2 27 (Ba) endurance at upper category temperature 1000 hours; 200 °C; no load no visible damage ∆R/R max.: ±5% + 0.1 Ω Other tests in accordance with IEC 60115 clauses and IEC 60068 test method 4.29 45 (Xa) component solvent resistance 70% 1.1.2 trichlorotrifluoroethane and 30% isopropyl alcohol; H20 no visible damage 4.18 20 (Tb) resistance to soldering heat 4.17 20 (Tb) solderability (after ageing) 16 hours steam or 16 hours at 155 °C; 2 ±0.5 s in solder at 235 ±5 °C; flux 600 good tinning (≥95% covered); no damage 4.5 tolerance on resistance applied voltage (±10%): R − Rnom: ±5% max. R<1 0 Ω : 0.1 V 10 Ω≤ R<1 0 0 Ω : 0.3 V 100 Ω≤ R<1k Ω : 1 V 1k Ω≤ R<1 0k Ω : 3 V 10 kΩ≤ R ≤ 33 kΩ : 10 V IEC 60115-1 CLAUSE IEC 60068 TEST METHOD TEST PROCEDURE REQUIREMENTS