4.5 Methods of examination and test. When applicable, testing of relays with plug-in terminations shall be
performed with the appropriate connector mated to the relay. When it is necessary to monitor contact operation
during the specified testing, the contact monitor used shall not load the respective contact in excess of .10 watt. A
NE-2 neon lamp in series with a 100,000 ohm resistor represents a suitable contact monitoring device.
4.5.1 Visual and mechanical examination (external). Relays shall be examined to verify that the external design
and construction, physical dimensions, materials, marking, and workmanship are in accordance with the applicable
requirements (see 3.1, 3.3, 3.4, 3.26, and 3.30).
4.5.2 Solderability (applicable to solder terminals) (see 3.5). Relays shall be tested in accordance with method
208 of MIL-STD-202. The following details apply:
a. Number of terminations of each part to be tested: All.
b. Depth of immersion in flux and solder: Leads shall be immersed to within .063 inch of the seal or case.
4.5.3 Dielectric withstanding voltage (see 3.6). Relays shall be tested in accordance with method 301 of
MIL-STD-202. The following details apply:
a. Points of application and magnitude of test voltage: See 3.1.
b. Maximum leakage current: 1.0 mA.
c. Duration of application: 60 seconds for qualification; 5 seconds for group A tests.
d. Examinations following tests: Relays shall be examined for evidence of arcing, flashover, insulation
breakdown, and damage.
4.5.4 Insulation resistance (see 3.7). Relays shall be tested in accordance with method 302 of MIL-STD-202.
The following details apply:
a. Test condition letter: A for relays with coil and contact ratings below 60 volts, and B for all others.
b. Points of measurement: See 3.1.
4.5.5 DC coil resistance (see 3.8). Relays shall be tested in accordance with method 303 of MIL-STD-202.
4.5.6 Pickup and dropout voltage (see 3.9). Relays shall be measured as specified in 18.104.22.168 and 22.214.171.124. The
relay mounting position shall be as specified in 3.1. A suitable indicating device shall be used to monitor contact
126.96.36.199 Pickup voltage. Rated voltage shall be applied to the coil for a period of 1 to 3 seconds. The voltage shall
be gradually reduced to zero, then gradually increased until the relay operates. The pickup voltage shall be
measured at this point.
188.8.131.52 Dropout voltage. Rated voltage shall be applied to the coil. The voltage shall be gradually reduced until
the contacts return to the deenergized position. The dropout voltage shall be measured at this point.
4.5.7 Coil power dissipation (when specified) (see 3.1 and 3.10). Relays shall have the coil energized with rated
voltage (see 3.1) with the relay stabilized at 25°C ±5°C. The coil power shall be measured within the first minute.