MIL-R-5757J
4.2.2 Grounding. Unless otherwise specified (see 3.1), the negative side of the dc power supply shall be grounded. One side of single phase ac power supply shall be grounded.
4.2.3 Load conditions during tests. The coil(s) of the relay under test shall have one side connected to the coil power supply ground. All tests during which the contacts are loaded and being cycled, except dielectric withstanding voltage, shall be conducted with the case of the relay connected to the power supply ground or neutral through a normal blow fuse rated at 5 percent of the contact load maximum, but not less than 0.100 ampere. For relays with nongrounded case ratings, tests for isolated-case ratings may be made with the case electrically isolated from the power supply ground.
4.2.4 Testing devices. Devices used in the testing of relays shall not load the contacts above 10 milliamperes
(mA) resistive at 6 V dc or peak ac maximum open circuit unless otherwise specified herein.
4.2.5 Mounting relays for ambient temperature tests. When the relays are subjected to the testing specified in
4.6.16 (coil life) and 4.6.22 (mixed loads), they may be mounted on a heat sink in accordance with the following:
a. Each relay may be attached by its normal mounting means to a .063 inch (1.59 mm) thick minimum, flat aluminum plate heat sink. The heat sink shall be designed to place every relay in the center of its own square space whose total surface area (both sides) is eight times the outside surface area of the relay, excluding mounting. Relays without mounts shall be held to the heat sink with a metal strap .250 inch (6.35
mm) wide by .015 inch (0.38 mm) maximum thickness. The heat sink assembly shall be suspended by twine or other nonheat conducting material. The leads shall not constitute a heat sink.
b. Chamber temperature shall be controlled to maintain the temperature at the specified ambient extremes (see
3.1).
4.2.6 Methods of examination and test. Application of coil power to relays under test shall be such that plus polarity is applied to the color coded terminal when applicable; or to the lower numbered terminal when color coding is not used.
4.2.7 Tolerances. Unless otherwise specified (see 3.1), all electrical, environmental, and mechanical parameters shall have a tolerance of ±10 percent.
4.2.8 Alternate test equipment. Test circuits and test equipment herein are intended to provide guidance to the relay manufacturer. Use of any alternate test circuits and/or test equipment shall be approved by the qualifying activity prior to use.
4.2.9 Test equipment and inspection facilities. The manufacturer shall establish and maintain a calibration system in accordance with ANSI/NCSL Z540.3, ISO-10012, or equivalent system as approved by the qualifying activity.
4.3 Qualification inspection. Qualification inspection shall be performed at a laboratory acceptable to the
Government (see 6.3) on sample units produced with equipment and procedures normally used in production.
4.3.1 Qualification. A certification of construction to the materials requirements of 3.3, and the interface and construction requirements of 3.4 shall accompany the submission of qualification inspection results to the qualifying activity.
4.3.1.1 Sample size. The number of relays to be subjected to qualification inspection shall be as specified in table I. The sample shall be selected from a production run and shall be produced with equipment and procedures normally used in production. The qualification sample shall be as defined in
table I.
4.3.2 Inspection routine. Sample units shall be subjected to qualification inspection outlined in table I, in the order shown, except that group Q2 through group Q7 inclusive, may be conducted concurrently. All sample units shall be subjected to the inspections of Q1. These sample units shall then be divided into six groups as specified in table I and subjected to the inspection specified for their particular group.
4.3.3 Failures. Failures in excess of those allowed in table I shall be cause for refusal to grant qualification approval.
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