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July 2016

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Subject:
From:
George Wenger <[log in to unmask]>
Reply To:
TechNet E-Mail Forum <[log in to unmask]>, [log in to unmask]
Date:
Thu, 28 Jul 2016 17:47:32 +0000
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Hi Steve, 

I haven't used a Simonds lead processor and I'm not sure how sensitive the relay glass to metal seal is but I think that both of the suggestions you have are as good as the pre-epoxy. If cutting and or forming the leads would damage the internal relay I would have assumed the component vendor would have epoxied the leads before selling the component. 


Regards, 

George 

George M. Wenger 
Failure Signature & Characterization Lab LLC 
609 Cokesbury Road, High Bridge, NJ 08829 
(908) 638-8771 (Home) (732)-309-8964 (Cell) 
[log in to unmask] 

----- Original Message -----

From: "Steve Gregory" <[log in to unmask]> 
To: [log in to unmask] 
Sent: Thursday, July 28, 2016 11:12:17 AM 
Subject: [TN] Prepping TO-5 can style Relay... 

Hi All, 

We're building a board for a customer that uses a 8-lead TO-5 style relay. 
The footprint on the board requires that the leads are spread out to a 
larger diameter circle than what diameter is when they come out of the body 
at the bottom of the relay. Here's the information for one of the relays, 
there are three others that are the same style: 

http://www.digikey.com/product-search/en?lang=en&site=us&WT.z_cid=ref_findchips_standard&mpart=PRMAC-26X 

So we have a Simonds CLP274 lead processor with a die that matches the 
footprint on the PCB: 

http://stevezeva.homestead.com/Simonds_CLP274.jpg 

We insert the part which spreads the leads out, then step on the pedal and 
a guillotine style blade shears the leads off. I've used the prep unit 
many, many time before at previous employers without issues. The customer 
is saying that prepping the leads in this unit is damaging the relay. So 
now we are to pot the leads before prepping them with a 2-part epoxy using 
a tooling fixture as a mold for the epoxy, and the potted relay looks like 
this: 

http://stevezeva.homestead.com/Potted_Relay.jpg 

Has anybody ever heard of this Simonds unit damaging relays like this? Has 
anybody had to add potting to a relay like this? I can understand wanting 
to keep the leads coming straight out of the bottom of the body before 
making the bend to match the footprint on the board, but I think I can use 
a Bivar permanent spacer and slip it over the lead and accomplish the same 
thing. Something like this: 

https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=2&ved=0ahUKEwiqk8zCt5bOAhWJ1IMKHebaCR8QFggxMAE&url=http%3A%2F%2Fwww.bivar.com%2Fportals%2F0%2Fproducts%2F616-070.pdf&usg=AFQjCNESVvvX6qOo_-0T94sAYNLP8AJ21Q&cad=rja 

Or even a nylon washer that matches the diameter of the lead pattern 
(.200") coming out of the bottom of the relay. Potting this relay is going 
to be very time consuming and there's going to be a risk of getting the 
epoxy on the leads that will ruin the solderability of the part. I'm just 
trying to understand if it is truly the Simonds prep unit causing the 
damage, and if this really is, and easier way other than potting them to 
accomplish the same thing. 

Thanks all! 

Steve Gregory 

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