Phoenix Passive Components POWER RESISTOR - PR02 FEATURES • Metal film; • High power in small package; • Different leads for different applications; • Several forming styles are available; • Defined interruption behavior (fusing time); • Non-flammable; • High stability, reliability and uniformity characteristics; • Several packing and taping configurations; • Precision tolerance is available (1%); • Good performance for pulse applications. MARKET SEGMENTS AND APPLICATIONS Industry sector Application segment End-user equipment Industrial Power supplies Power Motor speed controls Line protection resistor Telecom Data Communication Power supplies Amplifiers, Color monitor Sound & Vision Television, Consumer Video cassette recorder Kitchen Appliances Blender Lighting Ballast equipment Dashboard electronics Lighting equipment Automotive Electronic Systems Window/mirror steering ABS system, Alarm system Airbag, Electronic fuel injection TECHNOLOGY A homogenous film of metal alloy is deposited on a high grade ceramic body. After a helical groove has been cut in the resistive layer, tinned connecting wires of electrolytic copper or copper-clad iron are welded to the end-caps. The resistors are coated with a red, non-flammable lacquer, which provides electrical, mechanical and climatic protection. The encapsulation is resistant to all cleaning solvents in accordance with “MIL-STD- 202E, method 215” and “IEC 60068-2-45”. PR02 Revision on 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is Prohibited without the written consent of the copyright owner. Page 1 of 13 Phoenix Passive Components QUICK REFERENCE DATA PR02 ± ± ± ±5% PR02 ± ± ± ±1% (E24 serie) (E24/E96 series) DESCRIPTION Cu-lead FeCu-lead Cu-lead FeCu-lead Resistance range 0.33 Ω to 1MΩ 1Ω to 1MΩ 1Ω to 1MΩ Maximum dissipation at Tamb 70ºC 2W 1.3W 2W 1.3W Thermal resistance (Rth) 75K/W 115K/W 75K/W 115K/W Temperature coefficient ≤ ± 250 ppm/ºC Limiting voltage (DC or RMS) 500V (1) Rated Voltage Pn x R Basic specification IEC 60115-1 and 60115-4 Climatic category 55/155/56 (IEC 60068) Stability, ΔR/Rmax., after: ±5% +0.1Ω ±1% +0.1Ω Load ±3% +0.1Ω ±1% +0.1Ω Climatic test Resistance to Soldering heat ±1% +0.05Ω ±0.5% +0.05Ω Note: 1- Maximum rated voltage is the “Limiting voltage”. PR02 Revision on 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is Prohibited without the written consent of the copyright owner. Page 2 of 13 Phoenix Passive Components MECHANICAL DATA Axial style L2 L1 (0.031) (0.196 ± ± ± ±0.004) (0.040) (0 +0.118/-0) (0 236 ± ±0 019) ± ± Table 1. Mass per Type A L1 max L2max φ φDmax |B1-B2| φ φd φ φ φ φ 100 units 0.8 ± 0.03 Cu * 52 52 +1.5/-0 10 12 3.9 ± 1.2 (0.031 ±0.001 Cu*) PR02 (2.047 +0.059/-0) (0.394) (0.394) (0.153) (±0.047) 0.6 ± 0.05 FeCu 46 (0.024 ±0.002 FeCu) *Preferred type Dimensions in mm / (Inches) MOUNTING The resistors are suitable for processing on automatic insertion equipment, cutting and bending machines. A radial taped version economizes space on the PCB. The double kink style offers great advantages for manual insertion improving the mounting stability for the customer. They have a real snap in function to fix the resistor in PCB without weakening the connecting leads. PR02 Revision on 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is Prohibited without the written consent of the copyright owner. Page 3 of 13 Phoenix Passive Components ELECTRICAL CHARACTERISTICS DERATING The power resistor that the resistor can dissipate depends on the operating temperature Pmax X Tamb 120 100 80 60 40 20 0 -55 0 55 70 110 155 Tamb (ºC) Maximum dissipation (Pmax.) in percentage of rated power as a function of ambient temperature (Tamb.). APPLICATION INFORMATION Hot-spot Solder-spot Fig. 2 - φ 0.8mm Cu – leads Minimum distance from resistor body to PCB = 1mm Fig. 1 - φ 0.8mm Cu – leads Hot Spot temperature rise (ΔT) Temperature rise (ΔT) at the lead end as a function of dissipated power. (Soldering point) as a function of dissipated power at various leads lengths after mounting PR02 Revision on 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is Prohibited without the written consent of the copyright owner. Page 4 of 13 Pmax % Prated Phoenix Passive Components Hot-spot Solder-spot Fig. 4 - φ 0.6mm FeCu – leads Fig. 3 - φ 0.6mm FeCu – leads Minimum distance from resistor body to PCB = 1mm Hot Spot temperature rise (ΔT) Temperature rise (ΔT) at the lead end as a function of dissipated power. (Soldering point) as a function of dissipated power at various leads lengths after mounting. Fig. 6 - φ 0.8mm FeCu – leads Fig. 5 - φ 0.8mm FeCu – leads Minimum distance from resistor body to PCB = 1mm Hot Spot temperature rise (ΔT) Temperature rise (ΔT) at the lead end as a function of dissipated power. (Soldering point) as a function of dissipated power at various leads lengths after mounting. Note: The maximum permissible hot-spot temperature is 220ºC. PR02 Revision on 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is Prohibited without the written consent of the copyright owner. Page 5 of 13 Phoenix Passive Components Fig. 7 - Impedance as a function of applied frequency. Fig. 8 - Phase angle as a function applied frequency. PR02 Revision on 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is Prohibited without the written consent of the copyright owner. Page 6 of 13 Phoenix Passive Components PULSE LOADING CAPABILITIES Fig. 9 – Pulse on a regular basis, maximum permissible peak pulse power (^Pmax) as a function of pulse duration (ti). Fig. 10 - Pulse on a regular basis, maximum permissible peak pulse voltage (^Vmax) as a function of pulse duration (ti). PR02 Revision on 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is Prohibited without the written consent of the copyright owner. Page 7 of 13 Phoenix Passive Components INTERRUPTION CHARACTERISTICS The graph based on measured data under constant voltage conditions; these data may deviate according to the application. Fig. 11 - Time to interruption as a Fig. 12 - Time to interruption as a Fig. 13 - Time to interruption as a function of overload power for function of overload power for function of overload power for range: 0R33 ≤ Rn < 5R range: 5R ≤ Rn < 68R range: 68R ≤ Rn < 560R MARKING The nominal resistance and tolerance are marked on the resistor using four or five colored bands in accordance with IEC publication 60062 “color code for fixed resistors”. Standard values of nominal resistance are taken from the E24/E96 series for resistors with a tolerance of ±5% or 1%. The values of the E24/E96 series are in accordance with “IEC publication 60063”. ORDERING INFORMATION Table 2. Ordering code indicating resistor type and packaging ORDERING CODE 23xx xxx xxxxx BANDOLIER IN AMMOPACK BANDOLIER ON REEL LEAD ∅ TOL STRAIGHT LEADS TYPE % mm 52 73 52 (2.047) (2.847) (2.047) 1000 units 1000 units 5000 units 0.5 - 06 192 6xxxx - Cu 0.8 1 22 197 1xxxx 06 192 5xxxx (Cu 0.031) PR02 06 198 53xxx 22 194 13xxx 06 198 23xxx 5 FeCu 0.6 22 194 54xxx - - (FeCu 0.024) Dimensions in mm / (Inches) Note: For formed types see “Formed Types Specification” PR02 Revision on 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is Prohibited without the written consent of the copyright owner. Page 8 of 13 Phoenix Passive Components ORDERING CODE • The resistors have a 12 digit ordering code starting with 23 • The subsequent 6 or 7 digits indicate the resistor type and packaging see table 2. • For 5% tolerance 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 3. • For 1% tolerance the remaining 4 digits indicate the resistance value; - The first 3 digits indicate the resistance value. - The last digit indicates the resistance decade in accordance with table 3. Table 3. Last digit of 12NC RESISTANCE DECADE (5%) RESISTANCE DECADE (1%) LAST DIGIT 7 0.33 to 0.91Ω - 8 1 to 9.1Ω 1 to 9.76Ω 9 10 to 91Ω 10 to 97.6Ω 1 100 to 910Ω 100 to 976Ω 2 1 to 9.1kΩ 1 to 9.76kΩ 3 10 to 91kΩ 10 to 97.6kΩ 100 to 910kΩ 100 to 976kΩ 4 5 1MΩ 1MΩ Example: The ordering code for resistor type PR02 with Cu leads and a value of 750Ω 5%, supplied on a bandolier of 1000 units in ammopack, is: 2306 198 53751 NAFTA ORDERING INFORMATION – CROSS REFERENCE NAFTA ORDERING CODES Table 4. Ordering code indicating resistor type and packaging Tol. Resistance NAFTA SPQ Type 12NC Taping % range Part Number units 52 2306 198 53xxx 5083NWxxxxxJA8AFX 1000; ammopack (2.047) 52 ± 5 0.33Ω to 1MΩ 2306 198 23xxx 5083NWxxxxxJ12AFX 5000; reel (2.047) PR02 52 2322 194 54xxx 5083NWxxxxxJA8AFXF06 1000; ammopack (2.047) 52 2306 197 1xxxx 5083NWxxxxxFA8AF5 1000; ammopack (2.047) ± 1 1Ω to 1MΩ 52 2306 192 5xxxx 5083NWxxxxxJ12AF5 5000; reel (1.047) Dimensions in mm / (Inches) PR02 Revision on 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is Prohibited without the written consent of the copyright owner. Page 9 of 13 Phoenix Passive Components COMPOSITION OF OHMIC VALUE The ohmic value is represented by 5 digits; see table 5. Table 5. Examples of the ohmic value 5 Digits Value (All Other) 1 Ω 1R000 10R00 10 Ω 100R0 100 Ω 1 KΩ 1K000 10 KΩ 10K00 100K0 100 KΩ 1M000 1 MΩ PACKAGING Bandolier in ammopack Table 6. Product Quantity M N P Bandolier Width 78 60 262 52 +1.5/-0 (3.071) (2.362) (1.0315) (2.047 +0.059/-0) PR02 1000 92 60 262 73 ±1.5 (3.622) (2.362) (1.0315) (2.847 ±0.059) Dimensions in mm / (Inches) PR02 Revision on 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is Prohibited without the written consent of the copyright owner. Page 10 of 13 Phoenix Passive Components Bandolier on Reel (optional) P N M Table 7. Product Quantity M N P Q V R Bandolier Width 95 361 361 355 78 89 52 +1.5/-0 PR02 5000 (3.740) (14.212) (14.212) (13.976) (3.071) (3.504) (2.047 +0.059/-0) Dimensions in mm / (Inches) TESTS AND REQUIREMENTS Essentially all tests are carried out in accordance with the schedule of “IEC publication 60115-1”, category LCT/UCT/56 (rated temperature range: Lower category temperature, upper category temperature; 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 60068-2, “Recommended basic climatic and mechanical robustness testing procedure for electronic components” and under standard atmospheric conditions according to “EC 60068-1”, subclause 5.3. In Table 8 the tests and requirements are listed with reference to the relevant clauses of “IEC publications 60115-1 and 60068-2”; a short description of the test procedure is also given. In some instances deviations from the IEC recommendations were necessary for out method of specifying. All soldering tests are performed with mildly activated flux. Table 8. Test procedures and requirements IEC IEC REQUIREMENTS 60115-1 60068-2 TEST PROCEDURE CLAUSE TEST PR02 5% PR02 1% METHOD 4.4.1 Visual examination No holes; clean surface no damage PR02 Revision on 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is Prohibited without the written consent of the copyright owner. Page 11 of 13 Phoenix Passive Components IEC IEC REQUIREMENTS 60115-1 60068-2 TEST PROCEDURE CLAUSE TEST PR02 5% PR02 1% METHOD 4.4.2 Dimensions (outline) Gauge (mm) See table 1 4.5 Resistance Applied voltage (+0/-10%): R<10Ω: 0.1V 10Ω < R < 100Ω: 0.3V 100Ω < R <1 kΩ : 1V R - Rnom: R - Rnom: 1kΩ < R < 10 kΩ:3V max.: ± 5% max.: ± 1% 10 kΩ < R < 100 kΩ: 10V 100 kΩ < R < 1MΩ: 25V R = 1MΩ: 50V Insulation resistance Maximum voltage (DC) after 1 4.6.1.1 4 minute; metal block method. R min.: 10 MΩ ins Voltage proof on Maximum voltage 500V (RMS) 4.7 insulation during 1 minute; metal block No breakdown or flashover method. Temperature At 20/ LCT /20ºC and 20/ UCT ≤ ± 250ppm 4.8.4.2 coefficient / 20ºC: (TC ppm/ºC) 4.16 21 (U) Robustness of Terminations: -6 4.16.2 21 (Ua1) Tensile all samples Load 10N; 10s Number of failures:<1x10 -6 4.16.3 21 (Ub) Bending half number of Load 5N; 4 X 90º Number of failures:<1x10 samples o 4.16.4 21 (Uc) Torsion other half 3 x 360 in opposite directions No damage number of samples ΔR/Rmax.:±0.5% + 0.05Ω 4.17 Solderability 2s; 235ºC; Good tinning; no damage 8 hours steam or 16 hours 20 (Ta) o Solderability 155 C; leads immersed 6mm Good tinning (≥95% covered); (after ageing) for 2 ±0.5 s in a solder bath at no damage o 235 ± 5 C. 4.18 20 (Tb) Resistance to soldering Thermal shock: 3s; 350ºC ; ΔR/Rmax.: ΔR/Rmax.: heat 6mm from body ±1% + 0.05Ω ±0.5% +0.05Ω 30 minutes at LCT and 4.19 14 (Na) Rapid change of No visual damage 30 minutes at UCT; 5 cycles temperature ΔR/Rmax.: ΔR/Rmax.: ±1%+0.05Ω ±0.5% +0.05Ω Frequency 10 to 500 Hz, 4.22 6 (Fc) Vibration displacement 1.5mm or No damage acceleration 10g, three ΔR/Rmax.: ±0.5% +0.05Ω directions; total 6h (3x2h) 3 Climatic sequence R min.: 10 MΩ ins 4.23 30 (Db) Damp heat 4.23.3 st (accelerated) 1 cycle o 4.23.6 30 (Db) Damp heat 6 days; 55 C; 95 to 98% R.H. ΔR/Rmax.: ΔR/Rmax.: (accelerated) ± 3% + 0.1Ω ± 1% + 0.1Ω remaining cycles PR02 Revision on 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is Prohibited without the written consent of the copyright owner. Page 12 of 13 Phoenix Passive Components IEC IEC REQUIREMENTS 60115-1 60068-2 TEST PROCEDURE CLAUSE TEST PR02 5% PR02 1% METHOD o 3 3 (Ca) Damp heat 56 days; 40 C; 4.24.2 R min.: 10 MΩ ins (steady state) (IEC) 90 to 95% R.H; loaded with ΔR/R max.: ΔR/R max.: 0.01Pn (IEC steps: 4 to 100V) ± 3% + 0.1Ω ± 1% + 0.1Ω o Endurance (at 70 C) 1000h loaded with Pn or Vmax ΔR/Rmax.: ΔR/Rmax.: 4.25.1 1.5h on and 0.5h off ± 5% + 0.1Ω ± 1% + 0.1Ω 4.29 45 (Xa) Component solvent Isopropyl alcohol or H O 2 resistance followed by brushing in No visual damage accordance with “MIL 202F” nd See 2 amendment to Pulse Load See figs. 9 and 10 “ÏEC 60115-1”. PR02 Revision on 2003/03/26     PHOENIX DO BRASIL LTDA. All rights are reserved. Reproduction whole or in part is Prohibited without the written consent of the copyright owner. Page 13 of 13