DLA MIL-DTL-15109 D (1)-2013 RESISTORS AND RHEOSTATS NAVAL SHIPBOARD.pdf

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1、Comments, suggestions, or questions on this document should be addressed to: DLA Land and Maritime, ATTN: VAT, Post Office Box 3990, Columbus, Ohio 43218-3990 or by email Resistordla.mil. Since contact information can change, you may want to verify the currency of this address information using the

2、ASSIST Online database at https:/assist.dla.mil/. AMSC N/A FSC 5905 INCH-POUND MIL-DTL-15109D w/Amendment 1 7 November 2013 SUPERSEDING MIL-DTL-15109D 14 June 2001 DETAIL SPECIFICATION RESISTORS AND RHEOSTATS, NAVAL SHIPBOARD This specification is approved for use by all Departments and Agencies of

3、the Department of Defense. 1. SCOPE 1.1 Scope. This specification covers Class III shockproof resistors and rheostats for Naval shipboard service. 1.2 Classification. Resistors and rheostats of the following forms, as specified (see 6.2): Resistors: Form EW - Exposed wire or ribbon Form IW - Embedde

4、d wire or ribbon Form G - Grids or strips Form R - Ribbon Rheostats: Form EW - Exposed wire or ribbon Form P - Plate 2. APPLICABLE DOCUMENTS 2.1 General. The documents listed in this section are specified in sections 3, 4 and 5 of this specification. This section does not include documents cited in

5、other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements documents cited in sections 3, 4 and 5 of this specific

6、ation, whether or not they are listed. 2.2 Government documents. 2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cit

7、ed in the solicitation (see 6.2). DEPARTMENT OF DEFENSE SPECIFICATION MIL-S-901 - Shock Tests, H.I. (High-Impact); Shipboard Machinery, Equipment and Systems, Requirements for MIL-E-917 - Electric Power Equipment Basic Requirements Provided by IHSNot for ResaleNo reproduction or networking permitted

8、 without license from IHS-,-,-MIL-DTL-15109D w/Amendment 1 2 DEPARTMENT OF DEFENSE STANDARDS MIL-STD-167-1 - Mechanical Vibrations of Shipboard Equipment (Type I - Environmental and Type II - Internally Excited) (Copies of these documents are available online at http:/quicksearch.dla.mil or from the

9、 DLA Document Services, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094). 2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents cited in the solicitation or contract (

10、see 6.2). AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM) ASTM B117 - Standard Practice for Operating Salt Spray (Fog) Apparatus (DOD adopted) (Copies of these documents can be obtained online at http:/www.astm.org/ or by contacting ASTM International, P.O. Box C700, 100 Barr Harbor Drive, West Co

11、nshohocken, PA, 19428-2959). NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA) NEMA ICS 1 - Industrial Control and Systems, General Requirements (Copies of this document may be purchased from the National Electrical Manufacturers Association, 1300 North 17th Street, Suite 1847, Rosslyn, Virginia,

12、 United States, 22209. http:/www.nema.org/) 2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein (except for related specification sheets), the text of this document takes precedence un

13、less otherwise noted. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 3. REQUIREMENTS 3.1 Qualification. Resistors and rheostats furnished under this specification shall be products which are authorized by the qualifying ac

14、tivity for listing on the applicable qualified products list at the time of award of contract (see 4.2 and 6.3). 3.2 General requirements. Resistors and rheostats shall conform to MIL-E-917 and NEMA ICS 1 as specified herein. 3.2.1 Total resistance and tolerance. The total resistance of resistors an

15、d rheostats shall not differ from the design value by more than 10 percent. A variation of 20 percent will be permitted from the design values of any step or section. 3.2.2 Resistance value deviations. All maximum deviations as specified in this section are to be considered absolute limits with the

16、exception of the contact resistance adjustment. 3.3 Characteristics. Resistors and rheostats shall have the following characteristics, as specified (see 6.2f). 3.3.1 Voltage. Resistors and rheostats shall be designed for a maximum circuit voltage of 150, 300 or 600 volts alternating current (ac) roo

17、t mean square (rms) or direct current (dc) (see 6.2g). 3.3.2 Mounting. Resistor assemblies and rheostats shall be constructed for bulkhead, deck, or switchboard mounting, as specified. Individual resistor units shall be furnished with mounting brackets, mounting bolts for single-end mounting, or wit

18、hout mounting hardware, as specified (see 6.2h). Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-15109D w/Amendment 1 3 3.3.3 Duty. Unless otherwise specified, resistors and rheostats shall be constructed for continuous duty. If other duty, i

19、n the case of resistor applications, is required, NEMA ICS 1 standards for the specified duty shall apply (see 6.2i). 3.3.4 Ambient temperature. Unless otherwise specified (see 6.2), resistors and rheostats shall be constructed for a 50 degrees Celsius (OC) ambient. Where the normal temperature of t

20、he surrounding atmosphere exceeds 50OC, the rating shall be based on the specified ambient (see 6.2j). 3.3.5 Enclosures. Enclosures shall be open or drip proof, as specified (see 6.2k). Enclosures shall be furnished for resistors only when specified. If not specified, drip proof enclosures shall be

21、furnished for bulkhead mounted rheostats and open enclosures for switchboard mounted rheostats. Drip proof enclosures shall meet requirements of NEMA ICS 1 when inclined to any angle not greater than 45 degrees from the normal position and conform to the requirements of 3.5.4. 3.3.6 Temperature rise

22、. Temperature rises shall not exceed the values specified in NEMA ICS 1. 3.4 Construction. 3.4.1 Internal connections. Connections that are embedded in resistors and rheostats shall be soldered, welded, or brazed. Low melting solders that would be adversely affected by the operating temperature of t

23、he resistor or rheostat shall not be used. Connections shall be mechanically secure and electrically continuous. External connections to the resistors or rheostat shall be so that the heat from the resistor will not adversely affect the connection. 3.4.2 Rheostats. Rheostats shall be constructed to

24、ensure reliable operation under severe service. Springs shall not be stressed near or beyond their fatigue limits. Springs shall not carry current. Exposed metallic parts, other than terminals of plate type rheostats, shall be grounded. Two-terminal type rheostats shall be so connected internally th

25、at chatter under vibration or shock will not cause an open circuit. Rheostats shall be so arranged that speed, voltage, or other function being controlled is increased will clockwise rotation of the hand wheel. Dual purpose rheostats shall increase speed with clockwise rotation and increase voltage

26、with counter-clockwise rotation. 3.4.2.1 Brushes. The sliding brushes of plate type rheostats shall be easily renewable and so constructed as not to be blocked by slight projections on the fixed contact buttons. 3.4.2.2 Remote operation. When remote operation is required, a motor-driven operating me

27、chanism shall be provided consisting of the motor, gearing, limit switches, necessary shafting, and connections. An emergency manual operating feature shall be provided. 3.4.2.3 Interpolating. When interpolating rheostats (see 6.5.5) are required to obtain the necessary fineness of control, the resi

28、stance of the interpolating plate shall be not less than the three steps of the main plate, having the highest ohmic value. The ohms per step shall not exceed 0.4 percent of the total resistance of the main plate. 3.4.2.4 Interchangeability. In no case shall parts be physically interchangeable or re

29、versible unless such parts are also interchangeable or reversible with regard to function, performance and strength. 3.4.3 Pure tin. The use of pure tin, as an underplate or final finish, is prohibited both internally and externally. Tin content of resistor components and solder shall not exceed 97

30、percent, by mass. Tin shall be alloyed with a minimum of 3 percent lead, by mass (see 6.4). 3.5 Operational requirements. 3.5.1 Life. Resistors and rheostats shall be capable of withstanding the required electrical and mechanical life tests without a resistance change in excess of 10 percent (see 4.

31、5.8). Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-15109D w/Amendment 1 4 3.5.1.1 Electrical life. Continuously rated resistors and rheostats shall withstand 100 cycles of operation at 125 percent of the continuous duty wattage rating of t

32、he resistor or rheostat. Each cycle shall consist of 2 hours “on” and 2 hours “off”. Intermittently rated devices shall withstand 100 cycles of operation at 125 percent of the intermittent duty watt rating for the duty cycle specified. 3.5.1.2 Mechanical life. Rheostats, mechanically operated or mot

33、or driven, shall withstand 25,000 cycles of operation at rated load. Each operation shall cover at least 90 percent of the movement possible. 3.5.2 Salt spray. Resistors and rheostats shall withstand exposure to salt spray (see 4.5.9). The change in resistance shall not exceed 25 percent. 3.5.3 Vibr

34、ation. Resistors and rheostats shall withstand type I vibration tests of MIL-STD-167-1, without mechanical damage or malfunctioning (see 4.5.10). 3.5.4 Shock. Resistors and rheostats shall withstand the shock tests specified in MIL-S-901 (see 4.5.11). 3.5.5 Insulation resistance. Insulation resistan

35、ce, after completion of the electrical life and vibration tests, shall be not less than 50 megohms for resistors and 5 megohms for rheostats. (see 4.5.12) 3.6 Identification and information plates. Rheostats and resistors or rheostat assemblies shall be provided with an identification plate containi

36、ng the manufacturers name and catalog number, voltage, maximum and minimum amperes and ohms. Plates shall be brass or corrosion-resistant steel marked by etching, engraving, or stamping not less than 0.003 inch deep. Alternate methods of marking individual resistors shall be approved by the Command

37、or agency concerned. Such marking shall contain the manufacturers name or trademark, ohms, and watts. 3.7 Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or environmentally preferable materials should be used to the maximum extent possible provided that the materia

38、l meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle costs. 3.8 Workmanship. Resistors shall be processed in such a manner as to be uniform in quality and shall be free from cracked or displaced parts, sharp edges, burrs, and other defect

39、s which will affect life, serviceability, or appearance. 4. VERIFICATION 4.1 Classification of inspections. The inspection requirements specified herein are classified as follows: a. Qualification inspection (see 4.2). b. Retention of qualification inspection (see 4.3). c. Conformance inspection (se

40、e 4.4). 4.2 Qualification inspection. Qualification inspection shall consist of the applicable examination and tests of table I. Inspection shall be conducted at a laboratory satisfactory to the qualifying activity. 4.2.1 Number of samples. Three resistors or rheostats of each size and wattage shall

41、 be furnished. Minimum, median, and maximum resistance values shall be represented. 4.3 Retention of qualification. Every 12 months, one resistor and rheostat of each size and wattage shall be subjected to the retention of qualification inspection specified in table I. In the event that qualificatio

42、n tests are made on preproduction units, the first retention of qualification inspection shall be made on samples from the first production run. It is not required for the tests to be conducted on more than 1 out of 50 resistors or rheostats of a given design manufactured over a period of 3 years. P

43、rovided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-DTL-15109D w/Amendment 1 5 4.4 Conformance inspection. Each resistor and rheostat shall be subjected to the conformance inspection specified in table I. If this inspection reveals variations beyond n

44、ormal manufacturing tolerances, the Government may require that any portion, or all of the retention of qualification inspections be repeated to demonstrate conformance with this specification. TABLE I. Qualification, retention, and conformance inspections. Description and order of tests Requirement

45、 Test method Qualification Inspection Retention of qualification Conformance inspection Examination 3.2 4.5.1 X X X Weight 4.5.2 X X Electrical creepage and clearance 4.5.3 X X Resistance 3.2.1 4.5.4 X X X General operation 4.5.5 X X X Enclosures 3.3.5 4.5.6 X X Temperature rise 3.3.6 4.5.7 X X Life

46、 3.5.1 4.5.8 X Vibration 3.5.3 4.5.10 X Insulation resistance 3.5.5 4.5.12 X X Dielectric 4.5.13 X X X Shock 3.5.4 4.5.11 X X Salt spray 3.5.2 4.5.9 X 4.5 Test methods. 4.5.1 Examination. Each resistor or rheostat shall be subjected to examination to ascertain that the fit, materials and workmanship

47、 conform to this specification. 4.5.2 Weight. The weight of the equipment shall be taken and recorded. The weight shall not differ from the design value by more than 10 percent. 4.5.3 Electrical creepage and clearance distances. Electrical creepage and clearance distances shall be demonstrated by ac

48、tual measurement to be in accordance with MIL-E-917. 4.5.4 Resistance. The overall resistance of resistors and rheostats shall be measured to determine that they are within 10 percent of the design values. The temperature at which resistance readings are taken shall be recorded. 4.5.5 General operat

49、ion. General operation shall include any tests necessary to ascertain that the required operating requirements have been met. 4.5.6 Enclosures. No tests are required. Drip proof enclosures shall be given an examination to determine that falling moisture or dirt will not interfere with the mechanical or electrical operation of the equipment enclosed when inclined to any angle not exceeding 45 degrees from the vertical. 4.5.7 Temperature rise. The test methods to be empl