Phoenix Passive Components AXIAL WIREWOUND RESISTORS AC FEATURES • General purpose resistors; • High power dissipation in small volume; • High pulse load handling capabilities; • Different forming styles available; • High temperature silicone coating. MARKET SEGMENTS AND APPLICATIONS Market Segment Application Industrial Power supplies Motor speed controls Telecom Line protection resistor Power supplies Consumer Audio Editors Systems Sound & Vision High end hi-fi DAP Kitchen appliances White good Lighting Ballast equipment Automotive Dashboard electronics Electronic fuel injection TECHNOLOGY 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 resistor is coated with green silicon cement which 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”.The standard resistor is supplier with axial lead taped or with formed leads as a special type. AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 1 of 24 without the written consent of the copyright owner Phoenix Passive Components QUICK REFERENCE DATA DESCRIPTION AC01 AC03 AC04 AC05 AC07 AC10 AC15 AC20 Rated dissipation at T =40 °C 1W 3W 4W 5W 7W 10W 15W 20W amb Rated dissipation at T =70 °C 0.9W 2.5W 3.5W 4.7W 5.8W 8.4W 12.5W 16.0W amb 0.1Ω 0.1Ω 0.68Ω 0.82Ω 0.1Ω 0.1Ω 0.1Ω 1.2Ω Resistance range (E24 Series), to to to to to to to to (see note 1) 2.4kΩ 6.8kΩ 8.2kΩ 56kΩ 5.1kΩ 15kΩ 27kΩ 39kΩ Resistance tolerance (see note 2) ±5%; (see note 2) Maximum permissive 350ºC body temperature Temperature coefficient values <10Ω: +600 ppm/ºC ; values ≥10Ω: -80/+140 ppm/ºC (See note. 3) Climatic category (IEC 60 068) 40/200/56 Operator Temperature -40ºC to + 200ºC Basic specification IEC 60 115-1 Limit voltage V = Pn x R Stability after : Load, 1000 hours ΔR/Rmax.: ±5% +0.1Ω Soldering ΔR/R max.: ±0.5% +0.05Ω Climatic tests ΔR/Rmax.: ±1% +0.05Ω Short time overload ∆R/ Rmax.: ± 2% +0.1Ω Special product modifications available on request Note 1 Special resistives values; Low indutance styles Note 2 Tolerances.: 1% 3% 10% Note 3 Temperature coefficient ( ppm/ºC).: 30 / 50 / 90 Note 4 Terminal lengths and diameters Note 5 Terminal with special configuration cropped and formed, double kink, stand-up version etc. Application information available on request 1 - Pulse load behaviour 2 - High frequency behaviour (self inductance) AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 2 of 24 without the written consent of the copyright owner Phoenix Passive Components MECHANICAL DATA Axial style TYPE L max. D max. C D |||| B1-B2|||| A 10 4.3 32 ± 1.2 63 ± 2 AC01 ( 0.394 ) ( 0.169 ) ( 1.260 ) ( 0.047 ) ( 2.480 ± 0.079 ) 13 5.5 30 ± 1.2 63 ± 2 AC03 ( 0.512 ) ( 0.216 ) ( 1.181 ) ( 0.047 ) ( 2.480 ± 0.079 ) 17 5.7 28 ± 1.2 63 ± 2 AC04 ( 0.669 ) ( 0.224 ) ( 1.102 ) ( 0.047 ) ( 2.480 ± 0.079 ) 0.8 ± 0.03 17 7.5 28 ± 1.2 63 ± 2 AC05 ( 0.031 ± 0.001 ) ( 0.669 ) ( 0.295 ) ( 1.102 ) ( 0.047 ) ( 2.480 ± 0.079 ) 25 7.5 28 ± 1.2 73 ± 2 AC07 ( 0.984 ) ( 0.295 ) ( 1.102 ) ( 0.047 ) ( 2.874 ± 0.079 ) 44 8 28 ± 1.2 89 ± 2 AC10 ( 1.732 ) ( 0.315 ) ( 1.102 ) ( 0.047 ) ( 3.504 ± 0.079 ) 51 10 28 AC15 - - ( 2.008 ) ( 0.394 ) ( 1.102 ) 67 10 28 AC20 - - ( 2.638 ) ( 0.394 ) ( 1.102 ) Dimensions in mm ( inches ). AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 3 of 24 without the written consent of the copyright owner Phoenix Passive Components Terminal forming types available under request Double kink type Stand-up type Kink type S The dimension for leads forming to be define as a function of specific application. Radial tapped version (available for AC01 type) Detail AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 4 of 24 without the written consent of the copyright owner Phoenix Passive Components Parameter SymbolDimensions Tolerance Notes 4.1 Maximum body diameter D Máx. ( 0.161 ) 8.5 Maximum body length A Máx. ( 0.335 ) 0.8 + 0.06 / -0.05 Lead wire diameter d ( 0.031 ) ( +0.002 / - 0.002 ) 12.7 ± 1.0 Pitch of components P ( 0.500 ) ( 0.039 ) 12.7 ± 0.2 Feed hole pitch P O ( 0.500 ) ( 0.008 ) 1.0 In 20 Pitch error max. - - ( 0.039 ) spacing Feed-hole centre to lead at 3.85 ± 0.5 P 1 topside at the tape ( 0.151 ) ( 0.002 ) Feed hole centre to body 6.35 ± 1.0 P2 centre ( 0.250 ) ( 0.039 ) 5.0 + 0.5 / - 0.2 Lead-to-lead distance F ( 0.197 ) ( +0.002 / -0.008 ) ± 1.2 Component alignment Δh 0 ( 0.047 ) Component alignment 0 Δg ± 3º 18.0 ± 0.5 W Tape width ( 0.709 ) ( 0.002 ) 6.0 + 0.2 / - 0.5 Minimum hol down tape width W0 ( 0.236 ) ( +0.008 / - 0.002 ) 9.0 ± 0.5 Hole position W1 ( 0.354 ) ( 0.002 ) Maximum hold down tape 0.5 W2 Máx. position ( 0.020 ) 16.5 ± 0.5 Lead wire H0 ( 0.650 ) ( 0.020 ) Height of component from 32.0 H1 Máx. 23min tape centre ( 1.260 ) 4.0 ± 0.2 Feed hole diameter D 0 ( 0.157 ) ( 0.008 ) 0.9 Total tape thickness T Máx. 0.4min ( 0.035 ) Maximum length of snipped 11.0 L Máx. lead ( 0.433 ) Minimum lead wire (tape 2.5 L1 Mín. portion) shortest lead. ( 0.098 ) Dimensions in mm (Inches). AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 5 of 24 without the written consent of the copyright owner Phoenix Passive Components ELETRICAL CHARACTERISTICS DERATING The power that the resistor can dissipates depends on the operating temperature; see bellow. 100 90 50 0 70 -40 40 120 200 T.amb (ºC) Temperature rise of the resistor body as a function of the dissipation APPLICATION INFORMATION HOT SPOT Hot Spot temperature rise (ΔT) as a function of dissipated power. AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 6 of 24 without the written consent of the copyright owner P.max (%) Phoenix Passive Components SOLDER SPOT Lead length as a function of the dissipation with the temperature rise at the end of lead (soldering oint) AC01 AC03 AC04 AC05 AC07 AC10 AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 7 of 24 without the written consent of the copyright owner Phoenix Passive Components AC15 AC20 PULSE LOAD CAPABILITIES How to interpret the maximum allowed pulse load from the graphs see details and definitions on general introduction AC 01 – Single Pulse AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 8 of 24 without the written consent of the copyright owner Phoenix Passive Components AC 01 – Repetitive Pulse Pulse on regular basis;maximum permissible peak pulse power (Pmax) as a function of pulse duration (ti) AC 01 Pulse on regular basis;maximun permissible peak pulse voltage (Vmax) as a function of pulse duration (ti) AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 9 of 24 without the written consent of the copyright owner Phoenix Passive Components AC 03 – Single Pulse Pulse capability; W as a function of Rn. s AC 03 – Repetitive Pulse Pulse on regular basis;maximum permissible peak pulse power (Pmax) as a function of pulse duration (ti) AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 10 of 24 without the written consent of the copyright owner Phoenix Passive Components AC 03 Pulse on regular basis;maximun permissible peak pulse voltage (Vmax) as a function of pulse duration (ti) AC 04 – Single Pulse Pulse capability; W as a function of Rn. s AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 11 of 24 without the written consent of the copyright owner Phoenix Passive Components AC 04 – Repetitive Pulse Pulse on regular basis;maximum permissible peak pulse power (Pmax) as a function of pulse duration (ti) AC 04 Pulse on regular basis;maximun permissible peak pulse voltage (Vmax) as a function of pulse duration. AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 12 of 24 without the written consent of the copyright owner Phoenix Passive Components AC 05 – Repetitive Pulse Pulse capability; W as a function of Rn. s AC 05 – Repetitive Pulse Pulse on regular basis;maximum permissible peak pulse power (Pmax) as a function of pulse duration (ti) AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 13 of 24 without the written consent of the copyright owner Phoenix Passive Components AC 05 Pulse on regular basis;maximun permissible peak pulse voltage (Vmax) as a function of pulse duration (ti) AC 07 – Single Pulse Pulse capability; Ws as a function of Rn. AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 14 of 24 without the written consent of the copyright owner Phoenix Passive Components AC 07 – Repetitive Pulse Pulse on regular basis;maximum permissible peak pulse power (Pmax) as a function of pulse duration (ti) AC 07 Pulse on regular basis;maximun permissible peak pulse voltage (Vmax) as a function of pulse duration ti) AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 15 of 24 without the written consent of the copyright owner Phoenix Passive Components AC 10 – Repetitive Pulse Pulse capability; W as a function of Rn. s AC 10 – Repetitive Pulse Pulse on regular basis;maximum permissible peak pulse power (Pmax) as a function of pulse duration (ti) AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 16 of 24 without the written consent of the copyright owner Phoenix Passive Components AC 10 Pulse on regular basis;maximun permissible peak pulse voltage (Vmax) as a function of pulse duration (ti) AC 15 – Single Pulse Pulse capability; W as a function of Rn. s AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 17 of 24 without the written consent of the copyright owner Phoenix Passive Components AC 15 – Repetitive Pulse Pulse on regular basis;maximum permissible peak pulse power (Pmax) as a function of pulse duration (ti) AC 15 Pulse on regular basis;maximun permissible peak pulse voltage (Vmax) as a function of pulse duration (ti) AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 18 of 24 without the written consent of the copyright owner Phoenix Passive Components AC 20 – Single Pulse Pulse capability; W as a function of Rn. s AC 20 – Repetitive Pulse Pulse on regular basis;maximum permissible peak pulse power (Pmax) as a function of pulse duration (ti) AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 19 of 24 without the written consent of the copyright owner Phoenix Passive Components AC 20 Pulse on regular basis;maximun permissible peak pulse voltage (Vmax) as a function of pulse duration (ti) MARKING The resistor is marked with the nominal resistance value, the tolerance on the resistance and the rated dissipation at T = 40ºC. amb For values up to 910Ω, the R is used as the decimal point. For values of 1KΩ and upwards, the letter K is used as the decimal point for the KΩ indication. Example: 6K8 5% 5W AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 20 of 24 without the written consent of the copyright owner Phoenix Passive Components ORDERING CODE (12NC) The resistors have a 12-digit ordering code indicating the resistor type and resistive value. X X X X X X X X X X X X OHMIC VALUE PRODUCT ORDERING RESISTANCE NUMBER TYPE CODE DECADE AC01 2306 328 33 7 0.1 to 0.976Ω AC03 2322 329 03 8 1 to 9.76Ω AC04 2322 329 04 9 10 to 97.6Ω AC05 2322 329 05 1 100 to 976Ω AC07 2322 329 07 2 1 to 9.76kΩ AC10 2322 329 10 3 10 to 12kΩ AC15 2322 329 15 AC20 2322 329 20 Ordering example: The ordering code of the AC01 resistor, value 47Ω 5%, supplied in ammopack of 1000 units is: 2306 328 33479 NAFTA ORDERING INFORMATION - CROSS REFERENCE NAFTA ORDERING CODES The resistor have on ordering code with 12 digits, first 5 digits for product type and the subsequent digits indicate the resistance value and tolerance. Resistance Tol. Nafta part SPQ Type 12NC (1) range % Number units AC01 0.1 Ω to 2 KΩ ± 5 2306 328 33xxx AC01WxxxxxJ 1000; ammopack AC02 2306 326 33xxx AC02WxxxxxJ 500; ammopack 0.1 Ω to 4,7 KΩ ± 5 AC03 2322 329 03xxx AC03WxxxxxJ 500; ammopack 0.1 Ω to 4.7 KΩ ± 5 AC03 ± 5 2306 326 45xxx AC03WxxxxxJCF203 500; Box 0.1 Ω to 5.1 KΩ AC04 0.1 Ω to 6.8 KΩ ± 5 2322 329 04xxx AC04WxxxxxJ 500; ammopack AC05 2322 329 05xxx AC05WxxxxxJ 500; ammopack 0.1 Ω to 8.2 KΩ ± 5 AC05 2306 321 45xxx AC05WxxxxxJCF203 500; Box 0.1 Ω to 10 KΩ ± 5 AC07 ± 5 2322 329 07xxx AC07WxxxxxJ 500; ammopack 0.1 Ω to 15 KΩ AC10 0.68 Ω to 27 KΩ ± 5 2322 329 10xxx AC10WxxxxxJ 500; ammopack AC15 2322 329 15xxx AC15WxxxxxJ 100; Box 0.82 Ω to 39 KΩ ± 5 AC20 2322 329 20xxx AC20WxxxxxJ 100; Box 1.2 Ω to 56 KΩ ± 5 AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 21 of 24 without the written consent of the copyright owner Phoenix Passive Components COMPOSITION OF OHMIC VALUE The ohmic value is represented by 5 digits. 5 Digits Value (All Other) 1 Ω 1R000 10 Ω 10R00 100R0 100 Ω 1K000 1 KΩ 10 KΩ 10K00 100 KΩ 100K0 1M000 1 MΩ Ordering example: The ordering code for AC01, value 47Ω 5% , supplied in ammopack of 1000 units is: AC01W47R00J PACKAGING Axial resistor (taped or loose in box) TYPE QUANTITY M N P AC01 85 60 263 1000 Tape in box ( 3.346 ) ( 2.362 ) ( 10.354 ) AC03 85 77 259 500 Tape in box ( 3.346 ) ( 3.031 ) ( 10.197 ) AC04 85 77 259 500 Tape in box ( 3.346 ) ( 3.031 ) ( 10.197 ) AC05 85 112 259 500 Tape in box ( 3.346 ) ( 4.409 ) ( 10.197 ) AC07 93 115 259 500 Tape in box ( 3.661 ) ( 4.527 ) ( 10.197 ) AC10 110 117 275 500 Tape in box ( 4.331 ) ( 4.606 ) ( 10.827 ) AC15 140 60 335 100 Loose in box ( 5.512 ) ( 2.362 ) ( 13.189 ) AC20 140 60 335 100 Loose in box ( 5.512 ) ( 2.362 ) ( 13.189 ) Dimensions in mm ( inches ) AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 22 of 24 without the written consent of the copyright owner Phoenix Passive Components Axial resistor taped in reel (Special part number under request) TYPE QUANTITY AC01 4000 AC02 1500 AC03 1500 AC04 1500 AC05 1000 TESTS AND REQUIREMENTS Essentially all tests and requirements present in table bellow, follow the schedule of IEC standard, publication 60115-1, 60115-4 and 60068. IEC IEC 60068 60115-1 TEST PROCEDURE REQUIREMENTS TEST CLAUSE METHOD Temperature At 20/-40/20ºC. 4.8.4.2 coefficient 20/200/20ºC: Resistive value < 10Ω TC < ±600ppm/ºC - 80 ppm / ºC < TC Resistive value ≥ 10Ω TC< +140 ppm / ºC Temperature Horizontally mounted. Hot spot temperature less rise loaded with Pn than maximum body temperature. Short time overload Room temperature; ΔR/Rmax.: ± 2% + 0.1Ω 4.13 dissipation 10 x Pn; 5s (voltage not more than 1000V / 25mm) 4.15 Robustness of load 200 ± 10N no visible damage resistor body. ΔR/Rmax.:0.5%+ 0.05Ω AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is prohibited page 23 of 24 without the written consent of the copyright owner Phoenix Passive Components IEC IEC 60068 60115-1 TEST PROCEDURE REQUIREMENTS TEST CLAUSE METHOD 4.16 U Robustness of terminations: Ua Tensile all samples load 10N; 10s no visible damage Ub Bending half number load 5N; 90º. 180º. 90º ΔR/Rmax.: 0.5%+0.05Ω of samples o Uc Torsion other half 2 x 180 in opposite number of samples directions Ta Solderability Good tinning. 4.17 2s; 235ºCF; flux600 no visible damage Tb Resistance to Thermal shock: 3s; 4.18 soldering heat 350ºC, 2.5 mm from ΔR/Rmax.: 0.5%+0.05Ω body. o 14(Na) Rapid change of 0.5h - 40 C 4.19 no visible damage o temperature 0.5h + 200 C ΔR/Rmax.: 1% + 0.05Ω 5 cycles Fc Vibration Frequency 10 to 500 no visible damage 4.22 Hz. Displacement ΔR/Rmax.: 0.75mm or 0.5% + 0.05Ω acceleration 10g. three directions; total 6h (3x2h) Climatic sequence 4.23 o 16h. 200 C Ba Dry heat 4.23.2 o Damp heat 24h; 55 C; 4.23.3 Db (accelerated) 1st 95 - 100% R.H. cycle o 2h; -40 C Aa Cold 4.23.4 1h; 8.5 KPa; 4.23.5 M Low air pressure o 15 – 35 C o Damp heat 5 days; 55 C; 4.23.6 ΔR/Rmax.:1% + 0.05Ω Db (accelerated) 95 – 100% R.H. remaining cycles o 56 days; 40 C; No visible damage 4.24.2 Damp heat 3(Ca) 90 - 95% R.H. ΔR/Rmax.: 1% + 0.05Ω (steady state) dissipation ≤ 0.01Pn 1000h loaded with 0.9 Endurance No visible damage Pn; 1.5h on and 0.5h 4.25.1 o (at 70 C) ΔR/Rmax.: 5% + 0.1Ω off 27(Ba) Endurance at upper 1000 hours; 200ºC; no No visible damage 4.23.2 category temperature. load ΔR/Rmax.: 5% + 0.1Ω 45 (Xa) Component solvent 70% No visible damage 4.29 resistance trichlorotrifluoroethane and 30% isopropyl alcohol; H O 2 AC Revision in 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. 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