ISO 5867-1:1996

INTERNATIONAL Is0
STANDARD 5867-1
First edition
1996-02-01
Aircraft - Electromagnetic relays and
contactors -
Part 1:
General requirements
Akronefs - Relais et contacteurs 6lectromagrdtiques -
Partie I: Exigences g&Wales
Reference number
IS0 5867-1:1996(E)
IS0 5867=1:1996(E)
Contents
Page
..............................................................................................
1 Scope
.....................................................................
2 Normative references
.......................................................................................
3 Definitions
................................................................
4 General requirements
.....................................................
4.1 Detail specification sheets
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Temperature class
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Sealing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Altitudes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Dimensions
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Design requirements
. . . . . . . . . . . . . . . . . . . . . . . . .*.
4.7 Sealing enclosures
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8 Installation clearances
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9 Grounding
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10 Terminals
4.11 Contact symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.12 Materials
4.13 Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Performance detail requirements
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Examination of product
. . . . . . . 11
5.2 Environmental electrical and mechanical requirements
6 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . “.
6.1 Examination of product
. . 19
6.2 Test methods for electrical and mechanical requirements
7 Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .*.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Production acceptance tests
0 IS0 1996
All rights reserved. Unless otherwise specified, no part of this publication may be reproduced
or utilized in any form or by any means, electronic or mechanical, including photocopying and
microfilm, without permission in writing from the publisher.
International Organization for Standardization
Case Postale 56 l CH-1211 Geneve 20 l Switzerland
Printed in Switzerland
II
0 IS0 IS0 5867=1:1996(E)
7.2 Qualification inspection .
...................................................... 42
7.3 Retention of qualification
Annexes
. . . . . . . . . . . . . . . . . . . . . . . . . 45
A Example of an individual specification sheet
B Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . “.

0 IS0
IS0 5867=1:1996(E)
Foreword
IS0 (the International Organization for Standardization) is a worldwide
federation of national standards bodies (IS0 member bodies). The work
of preparing International Standards is normally carried out through IS0
technical committees. Each member body interested in a subject for
which a technical committee has been established has the right to be
represented on that committee. International organizations, governmental
and non-governmental, in liaison with ISO, also take part in the work. IS0
collaborates closely with the International Electrotechnical Commission
(IEC) on all matters of electrotechnical standardization.
Draft International Standards adopted by the technical committees are
circulated to the member bodies for voting. Publication as an International
Standard requires approval by at least 75 % of the member bodies casting
a vote.
International Standard IS0 5867-l was prepared by Technical Committee
ISO/TC 20, Aircraft and space vehicles, Subcommittee SC 1, Aerospace
electrical requirements.
IS0 5867 consists of the following parts, under the general title
Aircraft - Electromagnetic relays and con tactors:
- Part I: General requirements
Annexes A and B of this part of IS0 5867 are for information only.
iv
IS0 5867-1:1996(E)
INTERNATIONAL STANDARD 0 ISo
Electromagnetic relays and contactors -
Aircraft -
Part 1:
General requirements
IS0 1540:1984, Aerospace - Characteristics of air-
1 Scope
craft electrical systems.
This part of IS0 5867 specifies the performance re-
IS0 7137: 1995, Aircraft - Environmental conditions
quirements for electromagnetic relays and contactors
and test procedures for airborne equipment.
for use in nominal 28 V d.c. or 115 V/200 V 3-phase,
having the characteristics
400 Hz, ac. systems
I EC 50 (446): 1990, International ElectrotechnicaI Vo-
specified in IS0 1540.
Chapter 446: Electrical relays.
cabulary -
This part of IS0 5867 specifies the performance re-
I EC 68-2-l 7: 1994, Basic environmental testing pro-
quirements for relays and contactors having nominal
cedures - Part 2: Tests - Test 0: Sealing.
contact ratings of 5 A a.c., 5 A dc. or greater. Auxili-
ary contacts, where applicable, may be rated at lower
I EC 158-2: 1982, Low-voltage controlgear - Part 2:
Three temperature classes and three
currents.
Semiconductor contacters (solid state contactors).
classes of sealing are specified.
This part of IS0 5867 is applicable to single-pole and
multi-pole relays and contactors, electromagnetically
3 Definitions
operated and magnetically held, or electromag-
netically operated and mechanically or magnetically
For the purposes of this part of IS0 5867, the defi-
latched, controlled by a voltage of 28 V d.c. or 115 V, nitions given in IEC 50 (446) and IEC 158-2 apply.
400 Hz, a.c.
4 General requirements
2 Normative references
4.1 Detail specification sheets
The following standards contain provisions which,
through reference in this text, constitute provisions
The individual item requirements shall be as specified
of this part of IS0 5867. At the time of publication, the
in this part of IS0 5867 and in accordance with the
editions indicated were valid. All standards are subject
detail specification sheets related to this part of
to revision, and parties to agreements based on this
IS0 5867. In the event of any conflict between re-
part of IS0 5867 are encouraged to investigate the
quirements of this part of IS0 5867 and the detail
possibility of applying the most recent editions of the
specification sheets, the latter shall govern.
standards indicated below. Members of IEC and IS0
maintain registers of currently valid International The manufacturer shall prepare an individual specifi-
Standards. cation sheet for each type of device produced. The
0 IS0
IS0 5867~1:1996( E)
system having the characteristics specified in
individual specification sheet shall define the values
IS0 1540.
for parameters given in annex A.
The contacts of relays or contactors shall be capable
4.2 Temperature class
of switching 28 V dc. and/or 115 V/200 V a.c.,
400 Hz having a system characteristic specified in
The temperature classes which define the maximum
IS0 1540.
and minimum temperatures for use shall be as fol-
lows:
47 . Sealing enclosures
Class A: - 65 “C to + 125 “C
Sealing enclosures shall be of sufficient mechanical
Class B: - 55 “C to + 85 “C
strength to withstand the normal abuse incurred in
Class C: - 55 “C to + 70 “C
handling, transit, storage and installation without
causing malfunction or distortion of parts. The case
4.3 Sealing
shall not be a part of the contact or coil electrical cir-
cuits.
Enclosure design shall be classified as follows:
NOTE 1 The case may be a part of the magnetic circuit.
Class 1: Hermetically sealed
Class 2: Environmentally sealed
4.7.1 Hermetically sealed enclosures
Class 3: Ventilated enclosed
Hermetically sealed enclosures shall be constructed
4.4 Altitudes as a gastight enclosure that has been completely
sealed by fusion of glass or ceramic to metal, or
Class 1 and 2 sealed relays and contactors shall be
bonding of metal to metal. Hermetically sealed relays
suitable for use up to an altitude of 25 000 m.
and contactors shall be purged of all air. Relays shall
be filled with a suitable inert gas. The fill gas shall
Class 3 contactors shall be suitable for use up to an
have a dew point of at least 5 “C below the lowest
altitude of 15 000 m.
temperature rating of the device.
NOTE 2 Contactors may be filled with air or with inert
4.5 Dimensions
gas.
Relay and contactor dimensions shall be as defined in
4.7.2 Environmentally sealed enclosures
the detail specification sheet (see 4.1).
Environmentally sealed enclosures shall be con-
4.6 Design requirements
structed by any means other than that defined in 4.7.1
to achieve the degree of seal specified in the detail
The relays and contactors shall operate satisfactorily
specification (see 4.1). Environmentally sealed relays
when mounted in any attitude. The size and mass
and contactors shall be purged of all air. Relays shall
shall be the minimum compatible with the required
be filled with a suitable inert gas. The fill gas shall
performance, reliability and strength.
have a dew point of at least 5 “C below the lowest
temperature rating of the device.
The relays and contactors shall be of the single-pole
or multi-pole (main contacts) type, with or without
NOTE 3 Contactors may be filled with air or with inert
auxiliary contacts.
gas.
The auxiliary contacts shall be mechanically linked to
4.7.3 Ventilated enclosures
the main contacts and shall indicate the position of
the main contacts.
Ventilated contactors shall be totally enclosed for
mechanical and dust protection and shall be
Suitable barriers shall be placed between the ter-
explosion-proof. The enclosure shall be so designed
minals of the contactors in order to prevent an acci-
that when the cover is removed, the contactor shall
dental short-circuit. These barriers shall be sufficient
be capable of operating without adjustment. The en-
to prevent the short-circuiting of all the terminals
closure design shall be such that pressure differentiais
through the presence of a flat conducting part.
cannot exist between the inside and outside to ag-
gravate the moisture accumulation problem. The
The coil of the relay or contactor shall operate from
cover shall be rugged in design, constructed of high
either, but not both, a 28 V d.c. or 115 V a.c., 400 Hz
0 IS0 IS0 5867=1:1996(E)
impact materials, and securely mounted to the
m . . d. . 1
contactor. Iable 1 - strengtn ot tnreadea terminals (static
value of pull and torque)
Force Torque
Thread size
4.8 Installation clearances
Ibf N-m in.lbf
N
No. 4-40 UNC 22,2 5 0,497 4,4
Adequate clearance shall be provided for installation
No. 6-32 UNC 133 30 I,13 IO
of terminals and mounting hardware. Clearance for
No. 8-32 UNC 156 35 2,26 20
standard socket wrenches shall be provided. Special
No. IO-32
UNC 180 40 3,615 32
installation tools shall be avoided where possible.
No. IO-24
UNC 180 40 3,954 35
l/4-28 UNC 222 50 8,474 75
4.9 Grounding
S/16-24 UNF 311 70 11,298 100
3/8-24 UNF 445 100 16,948 150
The mounting sha II provide an effective electrical
7/16-20 UNF 445 100 16,948 150
contact to ground when the relay or contactor is
I/2-20 UNF 445 100 16,948 150
mounted.
Each terminal shall have a terminal seat that shall
4.10 Terminals
provide the normal current-conducting path. The di-
ameter of the seat shall not be less than the area
Metal covers shall be provided with a means for
necessary to ensure that the current density does not
grounding. Relays and contactors shall have electrical
exceed I,55 x IO6 A/m* (1 000 A/in*).
terminals as specified in the detail specification (see
. .
4 1)
NOTE 5 The seat does not include the cross-sectional
area of the stud.
No rotation or other loosening of a terminal shall occur
throughout the relay or contactor life.
Stud terminals shall be capable of accommodating
two lugs with hardware as specified. A minimum of
one and a half threads shall remain above the nut with
4.10.1 Terminal type
all parts tightened in place.
Power terminals of greater than 25 A rating shall be
of the threaded stud type. Terminals rated at 25 A or
less may be plug-in, solder hook, stud or screw ter-
4.10.1.2 Solder hook or straight terminals
minals.
Solder terminals shall be tin plated. The terminal de-
sign shall allow for at least two wires of relay rating
4.10.1 .I Threaded terminals and mounting studs
to be connected (see 4.1).
Stud terminals shall accept connections using
crimped type lugs made of copper or aluminium, or
copper bars. A flat washer having a diameter at least
4.10.1.3 Plug-in terminals
equal to that of the base of the terminal, and a self-
locking nut or standard nut with suitable locking
Plug-in terminals shall conform to the arrangement
washer shall be used on each terminal.
and dimensions necessary for proper mating with the
associated socket or connector.
No rotation or other loosening of a terminal, or any
fixed portion of a terminal, shall be caused by any
For plug-in relays, the mounting arrangement of the
mechanical forces specified in table 1 involved in the
relay and its corresponding socket shall be designed
connection or disconnection, throughout the life of
such that the entire weight of the relay shall be sus-
the relay or contactor.
pended and the stability of its mounting shall be pro-
vided by an auxiliary mounting means other than the
These are maximum values which shall not be ex-
electrical terminals of the socket. Relays with plug-in
ceeded.
terminals shall have the electrical and environmental
tests performed with the specified socket assembled
NOTE 4 For installation torque values, see the detail
specification (4.1). to the unit. Plug-in terminals shall be gold plated.

0 IS0
IS0 5867=1:1996(E)
NOTE 6 The seat area does not include the cross-
4.10.1.4 Screw terminals
sectional area of the stud.
4.10.2 Terminal marking
Screw terminals shall be supplied with hardware as
Terminal identification shall be durably and legibly
specified in the detail specification (see 4.1). The di-
marked as specified in tables 2 to 4. For dual coil re-
ameter of the seat shall be equal to, or greater than,
lays, the relationship between coil and contacts shall
the diameter across the corresponding lug designed
be as specified in table 5. The positive end of the coil
for the particular current. It shall not be less than the
(XI) shall be designated on the header by use of a
area necessary to ensure that the current density
contrast bead.
does not exceed I,55 x 1 O6 A/m* (1 000 A/in*).
Contact arrangements, symbols and terminal marking
Table 2 -
Double throw
Single throw
Form “ B “ Form “C“ Form “ K”
Form “A“
normally open normally closed (two position) three position centre off
Single
A1 -4 A2
A3 O-A A2 ;; > A2
Al W\ A2
A3 e
break
B1 -4 B2
83 o-+ 82 B3 - B2
Bl Wb B2
Bl W B3 W
c1 -4 c2
c3 o-y c2 :; > c2
Cl wk c2
c3 w
Form “Y“ Forrn “Z“ Form “ KK”
Form “X“
A3 o--r--o A4 Al o--r--o A2
Al WU A2 A3 WW A4
Double
A3 o--r-o A4
Al W W A2
Bl o-70 B2
83 o-w-o B4
break
83 o--o B4
Bl WW B2
Bl W1L-o 82 83 WV 64
c3 o-~-o c4
Cl w w c2
Cl 07 v-0 c2
c3 O-70 c4
c3 w Q c4
Cl w w t2
NOTE - Contacts are shown with coil(s) de-energized.
Table 3 - Auxiliary terminals
Double throw
Single throw
Change over
Normally open Normally closed
13 0-y 12 ;; - 12
11 w\ 12
23 o-- 22 '2: = 22
21 wb 22
33 - 32
33 o-+ 32
31 W\ 32
31 w
13 0-r 14
11 w w 12
13 07-O 14
11 w w 12
23 o-v-o 24
23 o-10 24
21 ww 22
21 w - 22
33 o--r_I--o 34
31 WW 32
33 o--r-o 34
31 W - 32
IS0 5867=1:1996(E)
Table 4 - Symbols and marking for terminals
Dual coil terminals
4.12 Materials
Table 5 - Dual coil markings
The materials shall conform to requirements specified
in 4.12.1 and 4.12.2 as applicable. When a definite
material is not specified, the selection of material shall
be at the discretion of the manufacturer. Materials
selected shall be such that the relays or contactors
meet the performance requirements and product
A3-A2 (or A3-A4)
characteristics specified in this part of IS0 5867.
4.12.1 Metals
Metals shall be of corrosion-resistant type and shall
be plated or treated to resist corrosion. Zinc plating,
cadmium plating or unfused pure tin plating shall not
be used on internal parts of hermetically sealed relays
4.10.3 Terminal covers and barriers
and contactors.
Unless otherwise specified in the detail specification
Relays and contactors with stud or screw terminals
(see 43, the use of dissimilar metals shall conform
shall be provided with adequate covering, or separ-
to table 6.
ation‘ of terminal parts to provide protection against
inadvertent shorting, grounding, or contact by per-
4.12.2 Non-metals
sonnel.
Non-metals, including protective finishes, shall:
Terminal covers and barriers shall be designed to
meet performance requirements applicable to the re-
a) be moisture-resistant;
lay or contactor. The enclosure(s) shall be so designed
that when the cover is removed, the relay or contactor
b) be non-toxic;
shall be capable of operating without adjustment. The
cover design shall be such that pressure differentials
c) be arc-resistant;
cannot exist between the inside and outside.
d) be flame-resistant;
Barriers may be removable, or may be integral
NOTE 7
e) be self-extinguishing;
with removable covers.
f) not support fungus growth.
They shall not be adversely affected by loss of char-
acteristics of composition in aircraft fluids at the tem-
peratures specified in 4.2.
4.11 Contact symbols
Materials in hermetically sealed envelopes are not re-
quired to meet the moisture- and fungus-resistance
Contact arrangements, symbols and terminals mark-
requirements.
ing shall be in accordance with tables 2 to 4.

IS0 5867=1:1996(E)
Table 6 - Dissimilar metals
Anodic
EMF
index Compatible couplesl)
Metallurgical category
Group No.
v 0,Ol v
1 Gold, solid and plated; gold- + 0,15
platinum alloys; wrought platinum
(most cathodic)
?
2 Rhodium plated on silver-plated + 0,05
copper
3 Silver, solid or plated; high silver al- 0 15
loys
- 0,15 30
4 Nickel, solid or plated; Monel’ metal,
high nickel-copper alloys
5 Copper, solid or plated; low brasses
or bronzes; silver sider; German sil-
ver; high copper-nickel alloys;
nickel-chromium alloys; austenitic
corrosion-resistant steels
6 Commercial yellow brasses and - 0.25
bronzes
High brasses and bronzes; naval
brass; Muntz metal
18 % chromium type corrosion-
resistant steels
9 Chromium, plated; tin, plated; - 0,45 60
12 % chromium type corrosion-
resistant steels
tin-lead - 0,50 65
10 Tin-plate; terne-plate;
solder
11 Lead, solid or plated; high lead al- - 0,55 70
loys
12 Aluminium, wrought alloys of the - 0,60 75
Duralumin type
- 0,70 85
13 Iron, wrought, gray, or malleable;
plain carbon and low alloy steels,
armco iron
14 Aluminium, wrought alloys other - 0,75 90
than duralumin type; alumitiium,
cast alloys of the silicon type
15 Aluminium, cast alloys other than - 0,80 95
silicon type; cadmium, plated and
chromated
16 Hotdip-zinc plate; galvanized - 1,05 120
steel
17 Zinc, wrought; zinc-base die-casting - 1,lO 125
alloys; zinc, plated i
18 Magnesium and magnesium-base - 1,60 175
alloys, cast or wrought (most
anodic)
1) Compatible couples: potential difference of 0,25 V max. between groups.
1 I
Q IS0 IS0 5867=1:1996(E)
4.12.2.1 Plastic material
5 Performance detail requirements
Plastic material shall conform to 4.12.2. In addition,
5.1 Examination of product
when subjected to any of the tests in this part of
IS0 5867, the plastic material shall not:
When relays or contactors are examined and tested
in accordance with 6.1, they shall conform to require-
support combustion;
a)
ments for materials, design, construction, physical di-
mension, weight, item marking and workmanship as
give off noxious gases in harmful quantities;
b)
specified in this part of IS0 5867 and in the detail
specification (see 4.1).
c) give off any gases in quantities sufficient to cause
explosion of a sealed housing;
5.1 .I Dimensions
give off any gases in a sealed housing that will:
d)
Dimensions shall be in accordance with 4.5.
1) cause contamination of the contacts or other
5.1.2 Header glass of hermetically sealed
parts of the component,
enclosures
2) form current-carrying tracks when subjected
Header glass or ceramic of relays and contactors shall
to arcing conditions.
be visually inspected for workmanship and finish us-
ing microscopic examination with x 10 magnification.
All relays shall meet the applicable seal requirements,
4.12.2.2 Ceramic
regardless of the acceptability of the header glass.
Ceramic insulating material shall conform to the detail
NOTE 9 In case of dispute, the relay may be subjected
specification (see 4.1 and 4.12.2). External ceramic
to the applicable seal requirement or any test deemed ap-
surfaces shall be glazed.
propriate in order to determine its integrity (see 6.12).
Header glass may have small irregularities, such as
4.12.2.3 Magnet wire
bubbles, chips, cracks, etc. The acceptability of these
Magnet wire shall conform to the detail specification defects is based on the following (see figure 1):
(see 4.1 and 4.12.2).
a) broken or open blisters having sharp edges are
not acceptable;
4.12.2.4 Rubber
b) blisters whose diameters exceed one-third of the
Rubber shall conform to the detail specification (see
radial distance between the terminal and the cor-
4.1 and 4.12.2).
responding header metal (for a cluster of blisters
the combined diameters apply) are not accept-
4.12.2.5 Semiconductors able;
c) foreign material in or on the surface of the glass
Semiconductors shall conform to the detail specifi-
is not acceptable;
cation (see 4.1).
d) dark spots (pigment concentrations) whose diam-
eters exceed one-third of the radial distance be-
4.13 Qualification
tween terminal and the corresponding header
metal are not acceptable;
Relays and contactors supplied in accordance with
this part of IS0 5867 shall be products that have been
e) circumferential cracks which extend more than
tested and which have satisfied the qualification in-
90” are not acceptable;
spection specified in 7.2. The qualification inspection
shall be performed on units produced from parts
f) radial cracks whose lengths exceed one-third of
made by production tools.
the distance between the terminal and corre-
sponding header metal are not acceptable;
Relays and contactors supplied in accordance
NOTE 8
with this part of IS0 5867 may be qualified by similarity to
g) tangential cracks that are not confined to a single
other relays or contactors in their generic family. The quali-
fying activity may require additional testing. zone are not acceptable;

IS0 5867=1:1996(E)
Acceptable
Not acceptable
Reference b)
Referencee)
Reference f)
Referenceg)
Referenceh)
NOTE - Dashed lines indicate radial distance between terminal and header metal, dividing the glass into three equal parts
(zones).
- Inspection aid
Figure 1
IS0 5867=1:1996(E)
0 IS0
5.1.4 Hold voltage
h) surface chips whose lengths or widths exceed
one-third the distance between the terminal and
When relays or contactors are tested in accordance
corresponding header metal are not acceptable;
with 6.1.4, there shall be no change in contact state
(neither an opening of contacts that are closed, nor
chipped menisci are acceptable to the extent that
closure of contacts that are opened) until the coil
they do not extend below the surface of the glass,
voltage is less than the hold voltage specified in the
and conform to h);
detail specification (see 4.1).
j) menisci that extend up the terminal greater than
0,51 mm (0,020 in) or one-third of the terminal
5.1.5 Coil resistance
diameter whichever is greater, are not acceptable;
When relays or contactors are tested in accordance
k) peripheral cracks at the boundary of the glass and
with 6.1.5, the dc. coil resistance (or the maximum
surrounding header metal are not acceptable;
coil current) shall be as specified in the detail specifi-
cation (see 4.1). If protective circuitry is involved d.c.
I) any terminals which appear to be separated from
coil resistance shall be substituted by coil current (see
the glass are not acceptable.
5.1.6).
5.1.6 Maximum coil current
5.1.3 Operating voltage
When relays or contactors are tested in accordance
with 6.1.6, the maximum coil current shall not exceed
the value specified in the detail specification (see
5.1.3.1 Pickup voltage
. .
4 1)
When relays or contactors are tested in accordance
5.1.7 Contact circuit voltage drop and contact
with 6.1.3.1, each set of contacts shall make positive
resistance
contact or open, as applicable, in the energized pos-
ition when a potential voltage not in excess of the
When relays or contactors are tested in accordance
specified pickup voltage is applied to the relay or
with 6.1.7, the voltage drop values measured at the
contactor coil. All normally open switching circuits
appropriate terminal with rated resistive current shall
shall close with positive contact and all normally
not exceed the values given in table7.
closed circuits, if applicable, shall open. Once the de-
vice has picked up, the contacts shall not change
For relays or contactors with auxiliary contacts rated
state (break and remake) when the coil voltage is in-
2 A or less, the contact resistance value shall be not
creased from the point of pickup to the maximum coil
greater than 0,05 Q prior to the load endurance (life)
voltage, excluding normal contact bounce. For quali-
cycling test and 0,15 a after the load endurance (life)
fication inspection, the pickup voltage shall fall within
cycling test.
the maximum specified when the relay or contactor
is mounted in each of three mutually perpendicular
5.1.8 Contact bounce, operating and release time
planes.
Release time is not applicable to latching relays.
5.1.3.2 Dropout voltage Photographic records of contact operating and release
times, and contact bounce at nominal coil voltage
This subclause is not applicable to latching relays. shall be taken for qualification test approval.
When relays or contactors are tested in accordance
When relays or contactors are tested in accordance
with 6.1.8, the contact bounce, operating and release
with 6.1.3.2, each set of normally open contacts shall
times shall be within limits specified in the detail
open, and each set of normally closed contacts shall
specification (see 4.1). The operating and release
close, as applicable, when the applied coil voltage is
times shall not include the contact bounce time. The
in the specified dropout voltage range. Excluding
operating time and release time of each pole of a
normal contact bounce, once the relay has dropped
multipole relay shall be within 1 ms of each other pole
out, the contacts shall not change state when the
voltage is reduced from the point of dropout to 0 V. of that relay for relays with contact ratings of 15 A or
For qualification inspection, the dropout voltage shall less, and within 2 ms for relays and contactors with
contact ratings greater than 15 A. Synchronized
be measured with the device in each of three mutu-
switching control parameters for auxiliary contacts
ally perpendicular planes.
0 IS0
IS0 5867=1:1996(E)
5.1 .I0 Insulation resistance
relative to main and each other shall be specified in
the detail specification (see 4.1). Unless make-
When relays or contactors are tested in accordance
before-break action is specified in the detail specifi-
with 6.1 .lO, the insulation resistance shall be
cation (see 4.1), double-throw relays or contactors
measured at a potential of (500 + 25) V d.c. between
shall show no evidence of any normally open contacts
all mutually insulated terminals and between ter-
closing before all normally closed contacts open; any
minals and case. The required value shall be reached
normally closed contacts shall not make before all
within 2 min after applying the test potential.
normally open contacts break. Contact break bounce
on release of normally open contacts when specified
Insulation resistance shall be a minimum value of
in the detail specification (see 4.1) shall be less than
100 Ma except after climatic tests when it shall be a
100 p.s.
minimum value of 50 MQ.
5.1.11 Low level run-in
Relays and auxiliary contacts shall be tested in ac-
5.1.9 Dielectric strength and leakage current
cordance with 6.1 .I 1 or 6.2.15.6 as appropriate. One
operation exceeding 100 Q dynamic contact circuit
When relays or contactors are tested in accordance
resistance shall constitute failure.
with 6.1.9, the insulation of the relays and contactors
shall be capable of withstanding, without damage, the
5.1 .I2 Sealing test
values specified in table8, or in the relevant detail
specificat.ion (see 4.1).
5.1.12.1 Class 1 relays and contactors
All a.c. voltages stated are r.m.s. voltages. The testing
When class 1 relays and contactors are tested in ac-
shall be carried out under standard sea level con-
cordance with 6.1.12, the leakage rate shall not ex-
ditions.
ceed 6,2 x 10m3 Pa=cm3/s per cubic centimetre
(1 x 1 O- 6 atm=cm3/s per cubic inch) of net sealed
Leakage current shall not exceed 1 mA and the rate
volume, except for relays of 32,8 cm3 (2 in3) net
of applied test voltage shall not exceed 250 V/s.
sealed volume or less, in which case the leakage rate
shall not exceed 6,2 x IO- 5 Pacm3/s per cubic centi-
The 1 min test is mandatory for qualification test only.
The 5 s to IO s test may be used for production ac- metre (I x 1 O- * atmcm3/s per cubic inch) of net
sealed volume.
ceptance testing.
Table 7 - Contact circuit voltage drop
Readings in volts
Before load cycling After load cycling
Class
Average
Average
Maximum individual reading Maximum individual reading
reading
reading
1 0,150 0,150
0,175
I 2 and 3 0,125 0,150 I 0,175
I 0,175 I 0,200 I
Table 8 - Minimum values for high voltage tests
28 V d.c. 5OOV, 50 Hzto60 Hz
1 min
115/200 V a.c. 1 25OV,50 Hzto60 Hz
1 min
28 V a.c. 6OOV, 50 Hzto60 Hz 5sto10s
1 5OOV,50 Hzto60 Hz
115/200 V a.c. 5sto10s
IS0 5867=1:1996(E)
0 IS0
5.2.3 Electromagnetic interference
5.1.12.2 Class 2 relays and contactors
5.2.3.1 Exported spikes
When class 2 relays and contactors are tested in ac-
cordance with 6.1.12, the leakage rate shall be as
when tested in accordance with
If applicable,
specified in the detail specification (see 4.1).
6.1 .I 4.1, the relays and contactors shall not generate
exported spikes (back EMF) in excess of the figures
specified in the detailed specification (see 4.1).
5.1.13 Marking
5.2.3.2 Imported spikes
In addition to the reference marking of the terminals
(see 4.10.2) each relay or contactor shall be clearly
When tested in accordance with 6.1 .I 4.2, the relays
and indelibly marked with the followina information:
”
and contactors shall accept imported spikes of
+ 600 V peak over sine wave width of 5 j.~ without
5867; -
a) a reference to this part of IS0
any damage to the relay or contactor coil or coil sup-
ication;
b) manufacturer ’s name or identi pression device.
Following this test, the relays or contactors shall con-
c) manufacturer ’s type number;
form to 5.1.3.1, 5.1.3.2, 5.1.5 and 5.2.3.1.
d) the nominal operating coil volt w;
5.2.3.3 Compass-safe distance
e) the rated voltage and resistive current;
When relays or contactors are tested in accordance
f) circuit diagram (de-energized);
with 6.2.3, they shall satisfy the compass-safe dis-
tance as specified in the detail specification (see
g) date code (year/week).
4.1). There shall be not more than I” deflection of the
compass when either the relay or contactor is tested
in both energized and de-energized condition.
5.2 Environmental electrical and mechanical
5.2.4 Strength of terminals
requirements
When relay or contactor terminals are tested in ac-
cordance with 6.2.4, they shall conform to 4.10 and
5.2.1 High temperature operation
table 1.
When relays or contactors are tested in accordance
5.2.5 Thermal shock
with 6.2.1, the requirements for pickup voltage and
dropout voltage shall conform to the detail specifi-
When relays or contactors are tested in accordance
cations (see 4.1).
with 6.2.5, there shall be no damage to the relay,
loosening of terminals, or cracking or flaking of the
glass insulation (other than cracking or chipping of the
5.2.2 Low temperature operation
glass meniscus).
When relays or contactors are tested in accordance
5.2.6 Sand and dust
with 6.2.2, there shall be no damage such as loosen-
ing of terminals, cracking or flaking of glass insulation
This subclause is only applicable to class 3 relays or
(other than crazing or chipping of the glass meniscus)
contactors.
or of the hermetic seal. Following the test and at the
specified low temperature, the pickup voltage, drop- When relays or contactors are tested in accordance
out voltage, and contact voltage drop shall conform to with 6.2.6, there shall be no evidence of damage
the detail specification (see 4.1). Devices which con- sufficient to impair the operation of the device.
tain permanent magnets in the magnetic circuit shall,
in addition to the above test, be subjected to the
5.2.7 Continuous current
demagnetizing effect of a sudden application of
When relays or contactors are tested in accordance
maximum coil voltage for one operation at the begin-
with 6.2.7, there shall be no damage such as loosen-
ning of the second 24 h period when the high tem-
ing of terminals or loss of seal, or any deterioration
perature pickup voltage shall conform to detail
of performance beyond the limits specified in the de-
specification (see 4.1).
0 IS0
IS0 5867=1:1996(E)
5.2.11 Salt spray (corrosion)
tail specification (see 4.1). The terminal temperature
rise shall not exceed 75 “C.
When tested in accordance with 6.2.11, the relay or
contactor shall show no evidence of corrosion suf-
5.2.8 Shock
ficient to impair the operation of the device.
When relays or contactors are tested in accordance
5.2.12 Ozone
with 6.2.8, there shall be no closing of open contacts
in excess of 1 ps, nor opening of closed contacts for
When relays or contactors are tested in accordance
a total time in excess of 10 ps. Following the shock
with 6.2.12, the device shall exhibit no cracking of
test there shall be no structural failure, loss of seal or
materials or other damage which will adversely affect
other damage that might impair the operation of the
subsequent performance of the device.
device. Latching type devices shall remain in each
I no voltage applied to the coil.
latched position wit
5.2.13 Acceleration
When relays or contactors are tested in accordance
5.2.9 Vibration
with 6.2.13, the contacts of the device shall remain in
the de-energized conditions with no voltage across
5.2.9.1 Sinusoida
the coil and in the energized position when the coil
voltage is reduced to 50 % of the nominal system
When relays or contactors are tested in accordance
voltage. There shall be no closing of open contacts in
with 6.2.9.2, there shall be no contact opening in ex-
excess of 1 ps. Latching devices shall remain in each
cess of 10 ps and the contact closing shall not exceed
latched position with no voltage applied to the coils.
1 ps, unless otherwise specified in the detail specifi-
Following the test there shall be no structural failure,
cation (see 4.1). The high temperature shall be the
loss of seal or other damage that impairs the oper-
maximum specified in the detail specification (see
ation of the device.
4.1). Following the resonance endurance and cycling
endurance tests, there shall be no structural failure,
5.2.14 Explosion-proofing
loss of seal or other damage that impairs the oper-
ation of the device. Latching type devices shall remain This test is applicable to unsealed contactors.
in each latched position with no voltage applied to the
When contactors are tested in accordance with
coils.
6.2.14, any explosion internal to the contactor shall
not rupture the case or ignite the external fuel mixture
5.2.9.2 Random
in the test chamber.
When relays or contactors are tested in accordance
5.2.15 Load and life (endurance)
with 6.2.9.3, there shall be no contact opening in ex-
cess of 10 ps and the contact closing shall not exceed
5.2.15.1 Overloads
1 ps, unless otherwise specified in the detail specifi-
cation (see 4.1). The high temperature shall be the
Monitoring of terminal temperature rise where appro-
maximum specified in the detail specification (see
priate is required only during qualification testing.
4.1). Following the endurance tests, there shall be no
structural failure, loss of seal or other damage that
5.2.15.1.1 Overload a.c. or d.c.
impairs the operation of the device. Latching type
devices shall remain in each latched position with no
When relays or contactors are tested in accordance
voltage applied to the coils.
with 6.2.15.1, there shall be no electrical failure, such
as contact sticking, welding or failure to make or
break the specified overload current. Blowing the fuse
5.2.10 Acoustical noise
connected between case and load system ground or
neutral shall constitute failure. The terminal tempera-
This test is applicable only if specified in the detail
ture rise shall not exceed 75 “C.
specification (see 4.1).
When relays or contactors are tested in accordance 5.2.15.1.2 Rupture
with 6.2.10, there shall be no contact opening in ex-
When relays or contactors are tested in accordance
cess of 10 ps and the contact closing shall not exceed
with 6.2.15.1.2, there shall be no electrical failure,
1 ps. There shall be no deterioration of device per-
such as contact sticking, welding or failure to make
formance or physical damage.
so IS0 5867~1:1996( E)
5.2.15.5 Mixed loads
break the specified rupture current. Blowing of the
I
;e connected between case and load systen
When specified in the detail specification (see 4.1)
ground or neutral shall constitute failure. The termina I
and tested in accordance with 6.2.15.5, multipole re-
temperature rise shall not exceed 75 “C.
lays or contactors shall be capable of switching low
level and high (or intermediate) level loads on adjacent
5.2.15.1.3 Circuit breaker compatibility
contacts. The requirements for endurance, intermedi-
ate current and low level shall apply to the contacts
This test is applicable only if specified in the detail
switching these loads.
specification (see 4.1).
5.2.15.6 Low level
When relays or contactors are tested in accordance
with 6.2.15.1.3, there shall be no evidence of contact
When relays are tested in accordance with 6.2.15.6,
welding or sticking and the contact voltage drop shall
one miss shall constitute failure. Monitoring of tem-
conform to 5.1.7 after the test. The terminal tem-
perature rise is not applicable.
perature rise shall not exceed 75 “C. Blowing of the
fuse connected between case and load system
5.2.15.7 Load transfer, single or polyphase a.c.
ground or neutral shall constitute a failure.
When polyphase load transfer is specified in the detail
5.2.15.2 Endurance (life)
specification (see 4.1) and the contactors are tested
in accordance wit I 6.2.15.7, there shall be no phase-
When tested in accordance with 6.2.15.2, relays or
to-phase arc-over
or welding (sticking) of contacts
contactors having two or more sets of contacts and
during testing. B
owing of the case-to-ground fuse
which are rated for multiphase (115/200 V a.c. three-
shall constitute fa lure.
phase) shall be capable of handling multiphase power
Phase-to-phase arcing shall
on adjacent contacts.
5.2.16 Contamination
constitute a failure. Relays or contactors shall be
tested for endurance at rated contact load in accord-
When tested in accordance with 6.2.16, relays or
ance with 6.2.15.2.1 to 6.2.15.2.7. Test duty cycle and
contactors shall show no evidence of attack or corro-
calibration of the various contact loads shall conform
to table 14. There shall be no mechanical or electrical
failure. Welding or sticking of contacts, failure to
5.2.17 Insertion and withdrawal force
make, carry or break the load, or blowing of the fuse
connected between case and load system ground or
When tested in accordance with 6.2.17, sockets and
neutral shall constitute a failure. The terminal tem-
connectors shall conform to the insertion and with-
perature rise shall not exceed 75 “C.
drawal forces specified in the detail specification (see
4 . 1) .
5.2.15.3 Mechanical life (endurance at reduced
5.2.18 Mechanical/electrical interlock
load)
This test is applicab le only if specified in the detail
The relay or contactor shall be capable of operating
specification (see 4.1 .
)
at 25 % of rated resistive load for four times the
minimum operating cycles for relays under 25 A con-
When contactors provided with a mechanical inter-
tact rating (resistive) and two times the specified
locking feature are tested in accordance with 6.2.18,
minimum operating cycles for contactors rated 25 A
it shall not be possible to close one set of contacts
and over. When the devices are tested in accordance
whenever the second set of contacts are maintained
with 6.2.15.3, they shall remain mechanically and
closed.
electrically operative. There shall be no indication of
mechanical resonance due to the frequency of ener-
5.2.19 Seal
gizing voltage.
When relays and contactors are tested in accordance
5.2.15.4 Intermediate current
with 6.2.19, hermetically sealed devices shall conform
to the seal design requirements described in
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