Phoenix Passive Components POWER RESISTOR - PR01 FEATURES • Metal film technology • High power in small package • High stability, reliability and uniformity characteristics • Good performance for pulse applications • Different leads for different applications • Various forming styles are available • Defined interruption behavior (fusing time) • Non-flammable • Various packing and taping configurations • Precision tolerance is available (1%) MARKET SEGMENTS AND APPLICATIONS INDUSTRY SECTOR APPLICATION SEGMENT END-USER EQUIPMENT Industrial Power Power supplies Motor speed controls Telecom Data Communication Line protection resistor Power supplies Sound & Vision Amplifiers Television, Color monitor Video cassette recorder Kitchen Appliances Blender Lighting Ballast equipment Electronic Systems Dashboard electronics Lighting equipment Window / mirror steering ABS system, Alarm system, Airbag Electronic fuel injection Consumer Automotive PR01 PHOENIX DO BRASIL LTDA All rights are reserved . Reproduction whole or in part is prohibited without the written consent of the copyright owner. Revision on 2003/12/21 Page 1 of 13 Phoenix Passive Components TECHNOLOGY A homogeneous 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-202, method 215 and IEC 60068-2-45. QUICK REFERENCE DATA PR01 ±5% (E24 series) DESCRIPTION PR01 ±1% (E24/E96 series) Cu / FeCu lead Resistance range 0.22 Ω - 1 MΩ Maximum dissipation at Tamb = 70 °C 1W Thermal resistance (Rth) 135 K/W Limiting voltage (DC or RMS) Rated voltage 1 Ω - 1 MΩ 350 V (1) Pn x R ≤ ±250 ppm/°C Temperature coefficient Basic specification IEC 60115-1 and 60115-4 Climatic category (IEC 60068) 55/155/56 Stability ∆R/Rmax after: Load ±5% + 0.1 Ω ±1% + 0.1 Ω Climatic tests ±3% + 0.1 Ω ±1% + 0.1 Ω Resistance to soldering heat ±1% + 0.05 Ω ±0.5% + 0.05 Ω (1) Maximum rated voltage is the limiting voltage PR01 PHOENIX DO BRASIL LTDA All rights are reserved . Reproduction whole or in part is prohibited without the written consent of the copyright owner. Revision on 2003/12/21 Page 2 of 13 Phoenix Passive Components MECHANICAL DATA AXIAL STYLE Fig. 1 Table 1. Mechanical Data. PRODUCT A L1 max PR01 52.0 + 1.5 / - 0.0 (2.05 + 0.06 / - 0.00) 6.5 (0.26) L2 max ∅D max 8.5 (0.34) 2.5 (0.10) B1-B2 ∅d S WEIGHT gr/100 pcs ±1.2 (±0.05) 0.58 ±0.05 Cu (0.023 ±0.002 Cu) 5.0 ±0.1 (0.20 ±0.01) 24.0 Dimensions unless specified 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. PR01 PHOENIX DO BRASIL LTDA All rights are reserved . Reproduction whole or in part is prohibited without the written consent of the copyright owner. Revision on 2003/12/21 Page 3 of 13 Phoenix Passive Components ELECTRICAL CHARACTERISTICS DERATING The power that the resistor can dissipate depends on the operating temperature. Fig. 2. Maximum dissipation (Pmax) in percentage of rated power as a function of ambient temperature (Tamb) APPLICATION INFORMATION Hot spot Solder spot Fig. 3. φ 0.58 mm Cu – leads Hot spot temperature rise (∆T) as a function of dissipated power Fig. 4. φ 0.58 mm Cu - leads Minimum distance from resistor body to PCB =1mm Temperature rise (∆T) at the lead end (solder spot) as a function of dissipated power at various leads lengths after mounting PR01 PHOENIX DO BRASIL LTDA All rights are reserved . Reproduction whole or in part is prohibited without the written consent of the copyright owner. Revision on 2003/12/21 Page 4 of 13 Phoenix Passive Components Hot spot Solder spot Fig. 6. φ 0.60 mm FeCu - leads Minimum distance from resistor body to PCB =1mm Temperature rise (∆T) at the lead end (solder spot) as a function of dissipated power at various leads lengths after mounting (preformed types only) Fig. 5. φ 0.60 mm FeCu – leads Hot spot temperature rise (∆T) as a function of dissipated power (preformed types only) Note: The maximum permissible hot spot temperature is 205 °C Fig. 7. Impedance as a function of applied frequency PR01 PHOENIX DO BRASIL LTDA All rights are reserved . Reproduction whole or in part is prohibited without the written consent of the copyright owner. Revision on 2003/12/21 Page 5 of 13 Phoenix Passive Components Fig. 8. Phase angle as a function applied frequency PULSE LOADING CAPABILITIES Fig. 9. Pulse on a regular basis, maximum permissible peak pulse power (^Pmax) as a function of pulse duration (ti) PR01 PHOENIX DO BRASIL LTDA All rights are reserved . Reproduction whole or in part is prohibited without the written consent of the copyright owner. Revision on 2003/12/21 Page 6 of 13 Phoenix Passive Components Fig. 10. Pulse on a regular basis, maximum permissible peak pulse voltage (^Vmax) as a function of pulse duration (ti) INTERRUPTION CHARACTERISTICS The graphs are based on measured data under constant voltage conditions; these data may deviate according to the application. Fig. 11. Time to interruption as a function of overload power for range: 0R22 ≤ Rn < 1R Fig. 12. Time to interruption as a function of overload power for range: 1R ≤ Rn < 15R Fig. 13. Time to interruption as a function of overload power for range: 16R ≤ Rn < 560R PR01 PHOENIX DO BRASIL LTDA All rights are reserved . Reproduction whole or in part is prohibited without the written consent of the copyright owner. Revision on 2003/12/21 Page 7 of 13 Phoenix Passive Components 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. LEAD ∅ TOL QTY pcs TAPING 5000 ±1% 0.58 Cu (0.023) 52.0 (2.05) 1000 ±5% 5000 PACKAGING ORDERING CODE REEL 2306 191 5xxxx AMMOPACK 2322 196 1xxxx AMMOPACK 2306 191 2xxx AMMOPACK 2306 197 53xxx AMMOPACK 2322 193 14xxx REEL 2306 197 23xxx Dimensions unless specified in mm (inches) The resistors have a 12 digit ordering code starting with 2306 or 2322. The next 5 digits indicate the resistor type and packaging see table 2. For 5% tolerance the last 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 last 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. PR01 PHOENIX DO BRASIL LTDA All rights are reserved . Reproduction whole or in part is prohibited without the written consent of the copyright owner. Revision on 2003/12/21 Page 8 of 13 Phoenix Passive Components Table 3. Last digit of ordering code. RESISTANCE DECADE (5%) RESISTANCE DECADE (1%) LAST DIGIT 0.22 - 0.91 Ω - 7 1 – 9.1 Ω 1 - 9.76 Ω 8 10 - 91 Ω 10 - 97.6 Ω 9 100 - 910 Ω 100 - 976 Ω 1 1 – 9.1 kΩ 1 - 9.76 kΩ 2 10 - 91 kΩ 10 - 97.6 kΩ 3 100 - 910 kΩ 100 - 976 kΩ 4 1 MΩ 1 MΩ 5 Example: PR01, 150 Ω, ±5%, ammopack 1000 pcs is 2306 197 53151 NAFTA ORDERING INFORMATION Table 4. NAFTA ordering code. LEAD ∅ TOL TAPING ±5% 52.0 (2.05) 0.58 Cu (0.023) ±1% QTY pcs PACKAGING NAFTA ORDERING CODE 5000 REEL 5073NWxxxxxJ12AFX 1000 AMMOPACK 5073NWxxxxxJA8AFX 5000 AMMOPACK 5073NWxxxxxJ18AFX 5000 AMMOPACK 5073NWxxxxxF18AF5 1000 AMMOPACK 5073NWxxxxxFA8AF5 5000 REEL 5073NWxxxxxF12AF5 Dimensions unless specified in mm (inches) The ohmic value in the NAFTA ordering code (see table 4) is represented by the “xxxxx” in the middle of the above ordering code. Table 5 gives some examples how to use these 5 digits. PR01 PHOENIX DO BRASIL LTDA All rights are reserved . Reproduction whole or in part is prohibited without the written consent of the copyright owner. Revision on 2003/12/21 Page 9 of 13 Phoenix Passive Components Table 5. Examples of the ohmic value. VALUE 5 DIGITS 1Ω 1R000 10 Ω 10R00 100 Ω 100R0 1 kΩ 1K000 10 kΩ 10K00 100 kΩ 100K0 1 MΩ 1M000 PACKAGING TAPE IN AMMOPACK Table 6. Ammopack. TAPING M N P QTY pcs 52.0 + 1.5 / - 0.0 (2.05 + 0.06 / - 0.00) 82 (3.3) 28 (1.2) 262 (10.4) 1000 52.0 + 1.5 / - 0.0 (2.05 + 0.06 / - 0.00) 78 (3.1) 100 (4.0) 260 (10.3) 5000 PRODUCT PR01 Dimensions unless specified in mm (inches) PR01 PHOENIX DO BRASIL LTDA All rights are reserved . Reproduction whole or in part is prohibited without the written consent of the copyright owner. Revision on 2003/12/21 Page 10 of 13 Phoenix Passive Components TAPE ON REEL Table 7. Reel. PRODUCT TAPING M N P Q V R QTY pcs PR01 52.0 + 1.5 / - 0.0 (2.05 + 0.06 / - 0.00) 92 (3.7) 311 (12.3) 311 (12.3) 305 (12.1) 75 (3.0) 86 (3.4) 5000 Dimensions unless specified in mm (inches) TESTS AND REQUIREMENTS Essentially all tests are carried out in accordance to the schedule of IEC publications 60115 – 1, category 55/155/56 (rated temperature range - 55 to +155 °C; damp heat, long term, 56 days and along the lines of IEC publications 60068-2); “Recommended basic climatic and mechanical robustness testing procedure for electronic components” and under standard atmosphere conditions according to IEC 60068-1 subclause 5.3, unless otherwise specified. In some instances deviations from IEC applications were necessary for our method specified. Table 8. Test and requirements. IEC 60115-1 CLAUSE 4.6.1.1 REQUIREMENTS IEC 60068-2 TEST METHOD TEST - Insulation resistance PROCEDURE PR01 5% 500 V (DC) during 1 minute; V-block method. PR01 1% Rins min 104 MΩ PR01 PHOENIX DO BRASIL LTDA All rights are reserved . Reproduction whole or in part is prohibited without the written consent of the copyright owner. Revision on 2003/12/21 Page 11 of 13 Phoenix Passive Components IEC 60115-1 CLAUSE 4.7 REQUIREMENTS IEC 60068-2 TEST METHOD TEST - Voltage proof on insulation 500 V (RMS) during 1 minute, V-block method. No breakdown or flashover Between - 55 °C and + 155 °C ≤ ±250 ppm/°C PROCEDURE PR01 5% 4.8 - Temperature coefficient 4.16 21(U) Robustness of terminations: 4.16.2 21(Ua1) Tensile all samples Load 10 N, 10s 4.16.3 21(Ub) Bending half number of samples Load 5 N, 4 X 90° 4.16.4 21(Uc) Torsion other half of samples 3 x 360° in opposite directions 4.17 20(Ta) Solderability (after ageing) 16 h 155 °C; immersed in flux 600, leads immersed 2 mm for 2 ±0.5 s in a solder bath at 235 ±5 °C 4.18 20(Tb) Resistance to soldering heat Thermal shock: 3 s; 350 ±10 °C; 6 mm from body 4.19 14(Na) Rapid change of temperature 30 minutes at – 55 °C and 30 minutes at + 155 °C; 5 cycles 4.22 6(Fc) 4.23 Vibration Frequency 10 to 500 Hz, displacement 1.5mm or acceleration 10g; three directions; total 6 hours (3 x 2 h) PR01 1% No damage ∆R/Rmax ±0.5% + 0.05 Ω Good tinning (≥ 95% covered) No damage ∆R/Rmax ±1% + 0.05 Ω ∆R/Rmax ±0.5% + 0.05 Ω No visual damage ∆R/Rmax ±1% + 0.05 Ω ∆R/Rmax ±0.5% + 0.05 Ω No damage ∆R/Rmax ±0.5% + 0.05 Ω Climatic sequence: 4.23.2 2(Ba) Dry heat 16 h; 155 °C 4.23.3 30(Db) Damp heat (accelerated) 1st cycle 24 h; 25 °C to 55 °C; 90 to 100% RH 4.23.4 1(Aa) Cold 2 h; - 55 °C 4.23.6 30(Db) Damp heat (accelerated) remaining cycles 5 days; 25 °C to 55 °C; 90to 100% R.H. Rins min 103 MΩ ∆R/Rmax ±3% + 0.05 Ω ∆R/Rmax ±1% + 0.05 Ω PR01 PHOENIX DO BRASIL LTDA All rights are reserved . Reproduction whole or in part is prohibited without the written consent of the copyright owner. Revision on 2003/12/21 Page 12 of 13 Phoenix Passive Components IEC 60115-1 CLAUSE 4.24 REQUIREMENTS IEC 60068-2 TEST METHOD 3(Ca) TEST PROCEDURE PR01 5% Damp heat (steady state) 56 days; 40 °C; 90 to 95% R.H. loaded with 0.01Pn 4.25.1 - Endurance (at 70 °C) 1000 h loaded with Pn or Vmax 1.5 h ON and 0.5 h OFF 4.29 45(Xa) Component solvent resistance Isopropyl alcohol followed by brushing in accordance with MIL STD 202 See 2nd amendment to IEC 60115-1 Pulse Load PR01 1% Rins min 103 MΩ ∆R/Rmax ±3% + 0.05 Ω ∆R/Rmax ±1% + 0.05 Ω ∆R/Rmax ±5% + 0.05 Ω ∆R/Rmax ±1% + 0.05 Ω No visible damage See figs. 9 and 10 PR01 PHOENIX DO BRASIL LTDA All rights are reserved . Reproduction whole or in part is prohibited without the written consent of the copyright owner. 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