Product 1 08-1 501 AMF Specification O20ct97 Reva System, 5 Position, Battery Interconnect 1. SCOPE 1.1. Content This specification covers performance, tests and quality requirements for the AMP* 5 position battery interconnect system. System consists of a battery housing assembly and a printed circuit board mounted header assembly. Battery housing and header assembly are loaded with contacts for resistive welding and thru-hole soldering respectively. 1.2. Qualification When tests are performed on subject product line, procedures specified in AMP 109 series specifications shall be used. All inspections shall be performed using applicable inspection plan and product drawing. 2. APPLICABLE DOCUMENTS The following documents form a part of this specification to the extent specified herein. Unless otherwise specified, latest edition of the document applies. In the event of conflict between requirements of this specification and product drawing, product drawing shall take precedence. In the event cf conflict between requirements of this specification and referenced documents, this specification shall take precedence. 2.1. AMP Documents A. 109-1: General Requirements for Test Specifications B. 109 Series: Test Specifications as indicated in Figure 1. (Comply with MIL-STD-202, MIL- STD-1344 and EIA RS-364) Cc. Corporate Bulletin 401-76: Cross-reference between AMP Test Specifications and Military or Commercial Documents D. 501-305: Test Report 3. REQUIREMENTS 3.1. Design and Construction Product shall be of design, construction and physical dimensions specified on applicable product drawing. 3.2. Materials A. Contact: (1) Battery: Copper alloy, nickel plating (2) Header: Copper alloy, nickel plating overall, tin-lead plating in solder tail area B. Housing: (1) Battery: Thermoplastic, black, UL94V-0 (2) Header: Thermoplastic, black, UL94V-0 3.3. Ratings A. Voltage: 50 vde B. Current: See Figure 4 for applicable current carrying capability Cc. Temperature: -30 to 70C EG 0410-0345-97, BAB AMP Incorporated, Harrisburg, PA This specification is a controlled document. 1of3 For latest revision call AMP FAX*/Product Info number 1-800-522-6752. * Trademark Copyright 1997 by AMP Incorporated. LOC B | Indicates change All rignts reserved. Form 404-38 20Nov96-ANF 3.4. Performance and Test Description 108-1501 Product is designed tc meet electrical, mechanical and environmental performance requirements specified in Figure 1. Unless otherwise specified, all tests shall be performed at ambient environmental conditions per AMP Specification 109-1. 3.5. Test Requirements and Procedures Summary Test Description Requirement Procedure Examination of product. Meets requirements of product drawing. Visual, dimensional and functional per applicable quality inspection plan. ELECTRICAL Termination resistance. 5.5 millionms maximum. AMP 109-6-1. Subject mated contacts assembled in housing to 50 mv maximum open circuit at 100 ma maximum. See Figure 3. Insulation resistance. 1000 megohms minimum. AMP Spec 109-28-4. Test between adjacent contacts of mated samples. Dielectric withstanding voltage. 150 vac at sea level. 50 vac at 50000 feet. AMP Spec 109-29-1. Test between adjacent contacts of mated samples. Temperature rise vs current. 30C nominal temperature rise at specified current. AMP Spec 109-45-1. Measure temperature rise vs current. See Figure 4. MECHANICAL Solderability. Solderable area shall have minimum of 95% solder coverage. AMP Spec 109-11-2. Subject contacts to solderability. Vibration, random. No discontinuities of 1 microsecond or longer duration. See Note. AMP Spec 109-21-7. Subject mated samples to 3.13 G's rms. 20 minutes in each of 3 mutually perpendicular planes. See Figure 5. Physical shock. No discontinuities of 1 microsecond or longer duration. See Note. AMP Spec 109-26-9. Subject mated samples to 100 G's sawtooth shock pulses of 6 milliseconds duration. 3 shocks in each direction applied along 3 mutually perpendicular planes, 18 total shocks. See Figure 5. Figure 1 (cont) Rev A 2of8 Form 404-34 20Nov96-ANF 108-1501 Test Description Requirement Procedure Durability. See Note. AMP Spec 109-27. Mate and unmate non-energized samples for 1000 cycles for battery housings and 5000 cycles for headers at maximum rate of 600 cycles per hour. Contact retention. Contacts shall not dislodge fram connector housing. AMP Spec 109-30. Apply load of 10 Newtons to contacts. Mating force. & Newtons maximum per contact. AMP Spec 109-42, Condition A. Measure force necessary to mate samples a distance of 3mm for mating orientation 1 and 5mm for mating orientation 2 from point of initial contact at maximum rate of 1.5mm per second. See Figure 6. Unmating force. 1 Newton minimum per contact. AMP Spec 109-42, Condition A. Measure force necessary to unmate samples at maximum rate of 1.5mm per second. ENVIRONMENTAL Thermal shock. See Note. AMP Spec 109-22. Subject mated samples to 25 cycles between -30 and 105C. Humidity-temperature cycling. See Note. AMP Spec 109-23-3, Condition B. Subject mated samples to 10 cycles between 25 and 65C at 95% RH. Temperature life. See Note. AMP Spec 109-43. Subject mated samples to temperature life at 105C for 480 hours. NOTE Figure 1 (end) Shalt meet visual requirements, show no physical damage and shail meet requirements of additional tests as specified in Test Sequence in Figure 2. Rev A 3of8 Form 404-34 20Nov96-ANF 3.6. Product Qualification and Requalification Test Sequence NOTE (a) (b) (c) (a) (e) 108-1501 Test Group (a) Test or Examination tfc) | 2 3 4 5 Test Sequence (b) Examination of product 19 71,9 71,8 71,3 71,3 Termination resistance 3,7 | 2,7 Insulation resistance 2,6 Dielectric withstanding voltage 3,7 Temperature rise vs current 3,8 Solderability 2 Vibration 6(e) Physical shock Contact retention 2 Durability Mating force Unmating force Thermal shock Humidity-tem perature cycling A(d} Temperature life 5 See Para 4.1.A. Numbers indicate sequence in which tests are performed. Each header assembly will mate with 7 battery housing only and both be subjected to 7000 cycles during durability cycling. Precondition header assembly with 5000 cycies durability. Each battery housing assembly will cycle with header assembly for 1000 cycles only. Therefore, after every 7000 cycles, the battery housing shail be replaced with a new housing until 5000 cycles is reached. Discontinuities shall not be measured. Energize at 18C level for 100% loadings as determined in AMP Specification 109-157. Figure 2 Rev A 4of8 Form 404-34 20Nov96-AME 108-1501 4, QUALITY ASSURANCE PROVISIONS 4.1. Qualification Testing A. Sample Selection Samples shall be prepared in accordance with applicable Instruction Sheets and shall be selected at random from current production. Test group 1 shall consist of a minimum of 12 header assemblies and 60 battery housing assemblies where a minimum of 6 header assemblies and 6 battery housing assemblies are used with each mating configuration per Figure 6. Test group 2 shall consist of minimum of 6 header assemblies and 30 battery housing assemblies and shall be used in mating orientation 1 per Figure 6. Test group 3 shall consist of minimum of 6 header assemblies and 6 battery housing assemblies and shall be used with mating orientation 1 per Figure 6. Test groups 4 and 5 shall consist of minimum of 6 header assemblies and 6 battery housing assemblies and shall be used with mating orientation 1 per Figure 6. B. Test Sequence Qualification inspection shall be verified by testing samples as specified in Figure 2. 4.2. Requalification Testing If changes significantly affecting form, fit or function are made to product or manufacturing process, product assurance shall coordinate requalification testing, consisting of all or part of original testing sequence as determined by development/product, quality and reliability engineering. 4.3. Acceptance Acceptance is based on verification that product meets requirements of Figure 1. Failures attributed to equipment, test setup or operator deficiencies shall not disqualify product. When product failure occurs, corrective action shall be taken and samples resubmitted for qualification. Testing to confirm corrective action is required before resubmittal. 4.4. Quality Conformance Inspection Applicable AMP quality inspection plan will specify sampling acceptable quality level to be used. Dimensional and functional requirements shall be in accordance with applicable product drawing and this specification. Rev A 5of 8 Form 404-34 20Nov96-AIViF 108-1501 2.0 ] na |; L CL, v) iY fp 1.57% mm @) i] BAANASAANAN a f 1.25 amt Figure 3 Termination Resistance Measurement Points Rev A 6 of 8 Form 404-34 20Nov96-AME 108-1501 (SASF) RATED CURREN: = NOTE 10) a DATA POINTS REGRESSION AMPS x = a a r ~ O 10 2U 30 0 50 60 0 80 30 WoC P10 AMBIEN! TEMPERATURF - DFGRFE OC MAXIVUM OPERATING TEMPCRATURE e Figure 4A Current Carrying Capability Equivalent Wire Gage (See Note) Connector Loading 5 5 5 0.4mm 0.2mm 0.144mm Single Contact 1.0 0.8179 0.6799 2 0.9757 0.7981 0.6634 3 0.8822 0.7217 0.5999 4 0.7960 0.6511 0.5412 5 0.7162 0.5858 0.4870 Current rating is based on same equivalent wire gage on both header and battery housing contacts. Equivalent wire gage refers to current rating of conductor equivalent to that of copper wire. Such conductor could be copper printed circuit board traces for header assembly contacts or conductive straps for battery housing assembly contacts. For example, if a printed circuit board trace is desired for only 1 header assembly coniact requiring a current rating of 7 amperes, then by referring to EIA RS-214, a 0.4mm? equivalent wire gage is necessary for a 30C temperature rise above ambient. Then, by referring to ANSIIPC-D-275 dated 09/91, a conductor width of approximately 1mm and a thickness of approximately 0.07mm are required. Derating is necessary for multiple contacts. This example uses a 1.57mm printed circuit board. Additional derating of 15% (current wise) is suggested for printed circuit board thickness of 0.8mm or less or conductor thickness of 0.708mm or thicker. Figure 4B Current Rating Rev A 7Yors Form 404-34 20Nov96-108-1501 ANF HOUSING ASSEHAL Y AN f TRY CONTACTS UEPER POCKET L HEADER ASSEMSLY ~ Pe Og gt / CLAMP oe i NN ne i Z t ot - TF 7 = RD ie we LLG WR OTR EEE MLE E ES Z vey LLG MAOLELD LARA L EELS LEE, Mises Oe PALL oe Oy Wie My / ee Vg 4p 1. S?aq PO SBAl LOWE CLAM ne er ty VILLE bY bodid df ee Ye : Vn Cee VISRATION/SHOCK TABLE eee ie a AN SIMULATE MASS (260 GRAMS) [INSIDE HOUSING ASSEMELY Figure 5 Vibration & Physical Shock Mounting Fixture (1) 180 Mating -s <_< SSS 4 4, .5% mm 30 1.25 mm 3 @) 30 Mating + degree 270 Figure 6 Mating Orientation 8of 8 Rev A Form 404-34 20Nov96-