4995 COPYRIGHT 1981, BY AMP INCORPORATED ALL RIGHTS RESERVED. AN> QUALIFICATION TEST REPORT FIVE POSITION BATTERY INTERCONNECT SYSTEM 501-305 Rev. O Product Specification: 108-1501 CTL No.: CTL1878-038-001 CGL No.: CGL 1878-31 Date: June 12, 1995 Classification: Unrestricted Prepared By: W.L. Scharff CONTROLLED DOCUMENT This report is a controlled document per AMP Specification 102-21. It is subject to change and Corporate Standards should be contacted for the latest revision. L_____. Corporate Test Laboratory Harrisburg, Pennsylvania TO910006.106 4/95OWUWWWMWHHWWWWHW NNRNNNNNNNNYNNNNNN Foes ans abwWNH - oO mahwWN - - 501-305 Rev. O Table of Contents Page Introduction . 0. ee ee 1 PUTPOSE 2. ee ee ees 1 Scope 0. een er ere eee ss 1 Conclusion 2... 000. ee eee ees 1 Product Description 2.2... 00 ee et ee es 2 Test Samples... 6... cc ee ees 2 Qualification Test Sequence 2.6... ee ee es 3 Summary of Testing .. 10... - eee ee ees 4 Examination of Product .....-- 60. cee eee tee 4 Termination Resistance, Dry Circuit 2.6... eee es 4 Dielectric Withstanding Voltage ... 0... 6. 4 Insulation Resistance 1.0... eee ee ee es 4 Temperature Rise vs Current .. 2.0. ee eee tee 4 Vibration 0... ee es 4 Physical Shock 6... ee ee tt ee es 4 Mating Force 2.2... ee et ee tne 5 Unmating Force ...... 22-0 e eee eee Vc ee ee eee 5 Contact Retention 2.0... eee es 5 Durability 66.0 ee ees 5 Solderability .. 0.0 ee te eet es 5 Thermal Shock... 0.2... 0c cee ee eS 5 Humidity-Temperature Life... 2... ee eee es 5 Temperature Life 2.6... ee ee ees 5 Test MethodS ...--. ce eee ee eee 5 Examination of Product ....... 000. e ee ee en es 5 Termination Resistance,Dry Circuit... 2... 0. ee ees 5 Dielectric Withstanding Voltage ... 6... ee ee 6 Insulation Resistance 1.0... eee ee 6 Temperature Rise vs Current 2.0... eee ee eee 6 Vibration . 0. 6 Physical Shock 2... 2c cece ee ee ees 7 Mating Force 2... ee ee 7 Unmating Force 2... ee ee ee eee 7 Contact Retention .....0.. 00.0 et ee 7 Durability 2... ee 7 Solderability 2.0... ee ee eee ee es 7 Thermal Shock . 0... ee 7 Humidity-Temperature Life... 00 ees 8 Temperature Life 2... 1 ee es 8 Validation . 0... ee ee 9 (R1878WS)AMP AMP INCORPORATED HARRISBURG, PENNSYLVANIA 17105 PHONE: 717-231-3222 FAX: 717-231-3283 CORPORATE TEST LABORATORY Qualification Test Report 1. 1.4 1.2 1.3 Introduction Purpose Testing was performed on AMP* 5 position battery interconnect system to determine its conformance to the requirements of AMP Product Specification 108-1501 Rev. O. Scope This report covers the electrical, mechanical, and environmental performance of the 5 position battery interconnect system manufactured by the Business Development Division of the Capital Goods Business Unit. The testing was performed between February 8, 1995 and May 26, 1995. Conclusion The 5 position battery interconnect system meets the electrical, mechanical, and environmental performance requirements of AMP Product Specification 108-1501 Rev. O. * Trademark 501-305 Rev O Page 1 of 9501-305 Rev. O Page 2 1.4 1.5 Product Description The AMP 5 position battery interconnect system consists of a battery housing assembly and a printed circuit board mounted header assembly. The battery housing and header assembly are loaded with contacts for resistive welding and thru-hole soldering respectively. Test Samples The test samples were randomly selected from normal current production lots, and the following part numbers were used for test: TEST MATING QUANTITY PART DESCRIPTION GROUP ORIENTATION NUMBER See Fig. 1 1 1 30 787242-1 BATTERY ASSEMBLY " 1 6 787145-1 HEADER . 2 30 787242-1 BATTERY ASSEMBLY . 2 6 787145-1 HEADER 2 1 6 787242-1 BATTERY ASSEMBLY " 1 6 787145-1 HEADER 3 1 6 787242-1 BATTERY ASSEMBLY " 1 6 787145-1 HEADER 4 1 6 787242-1 BATTERY ASSEMBLY " 1 6 787145-4 HEADER 5 1 6 787242-1 BATTERY ASSEMBLY " 1 6 787145-1 HEADER QPORIENTATION 1 lo ORIENTATION 2 Figure 1 Mating Orientations501-305 Rev. 0 Page 3 1.6 Qualification Test Sequence Test Groups Test or Examination 1(a) 2 3 4 5 Test Sequence (a) Examination of Product 1,9 1,9 1,8 1,3 1,3 Termination Resistance, Dry Circuit 3,7 2,7 Dielectric Withstanding Voltage 3,7 Insulation Resistance 2,6 Temperature Rise vs Current 3,8 6(c) Vibration Physical Shock Mating Force Oni aya Unmating Force Contact Retention 2 Durability 4 Solderability 2 Thermal Shock 4 Humidity-Temperature Cycling 4(b) Temperature Life 5 {a} The numbers indicate the sequence in which tests were performed. (b) Precondition header assemblies with 5000 cycles durability. Each battery housing assembly was cycled with a header assembly for 1000 cycies only. The battery housings were replaced every 1000 cycles until 5000 cycles had been performed on the header assemblies. (c) Energized at the 18 degrees C level.501-305 Rev. O Page 4 2. Summary of Testing 2.1 Examination of Product - All Groups All samples submitted for testing were selected from normal current production lots. They were inspected and accepted by the Product Assurance Department of the Capital Goods Business Unit. 2.2 Termination Resistance, Dry Circuit - Groups - 1&2 All termination resistance measurements, taken at 100 milliamperes DC and 50 millivolts open circuit voltage were less than 5.5 milliohms. TEST MATING NUMBER CONDITION MINIMUM | MAXIMUM | AVERAGE GRoup | ORIENTATION | OF DATA See Fig. 1 POINTS Milliohms Milliohms Milliohms 1 1 30 INITIAL 1,62 2.57 1.904 1 1 30 AFTER MECHANICAL 1,54 4.03 2.295 1 2 30 INITIAL 1.63 2.10 1.798 1 2 30 AFTER MECHANICAL 1.73 3.54 2.373 2 1 30 INITIAL 1.45 2.17 1.625 2 1 30 AFTER TEMP LIFE 1.72 3.23 2.188 2.3. Dielectric Withstanding Voltage - Group - 3 No dielectric breakdown or flashover occurred when a test voltage was applied between adjacent contacts. 2.4 Insulation Resistance - Group - 3 All insulation resistance measurements were greater than 1000 megohms. 2.5 Temperature Rise vs Current - Group - 2 All samples had a temperature rise of less than 30C above ambient when a specified current of 8.74 amperes DC was applied. 2.6 Vibration - Group - 1 No discontinuities of the contacts were detected during vibration. Following vibration, no cracks, breaks, or loose parts on the connector assemblies were visible. 2.7. Physical Shock - Group - 1 No discontinuities of the contacts were detected during physical shock. Following physical shock testing, no cracks, breaks, or loose parts on the connector assemblies were visible.501-305 Rev. O Page 5 2.8 2.9 2.11 3.4 3.2 Mating Force - Group -_1 All mating force measurements were less than 40 newtons. Unmating Force - Group - 1 All unmating force measurements were greater than 5 newtons. Contact Retention - Group - 4 The contacts were not displaced from the specified interface dimensions as a result of applying a 22 newton force to each contact for 10 seconds in each direction. Durability - Group - 1 No physical damage occurred to the header samples as 4 result of mating and unmating the connectors 5000 times each. Additionally, no physical damage occurred to any of the battery housing assemblies as a result of mating and unmating 1000 times. Solderability - Group - 5 The contact leads had a minimum of 95% solder coverage. Thermal Shock - Group - 3 No evidence of physical damage to either the contacts or the connector was visible as a result of thermal shock. Humidity-Temperature Cycling - Groups - 2. & 3 No evidence of physical damage to either the contacts or the connector was visible as a result of exposure to humidity-temperature cycling. Temperature Life - Group - 2 No evidence of physical damage to either the contacts or the connector was visible as a result of exposure to an elevated temperature. Test Methods Examination of Product Product drawings and inspection plans were used to examine the samples. They were examined visually and functionally. Termination Resistance, Low Level Termination resistance measurements at low level current were made using a four terminal measuring technique (Figure 2). The test current was maintained at 100 milliamperes DC with an open circuit voltage of 50 millivolts DC.501-305 Rev. O Page 6 3.3 3.4 3.5 3.6 2.0 mre 1.25 mw Figure 2 Typical Termination Resistance Measurement Points Dielectric Withstanding Voltage A test potential of 150 vac was applied and maintained for a period of one minute between the mated adjacent contacts. Next a potential of 50 vac was applied and maintained for a period of one minute between the mated adjacent contacts while the samples were soaked in an altitude chamber at a pressure equal to 50,000 feet above sea level. Insulation Resistance Insulation resistance was measured between adjacent contacts, using a test voltage of 500 volts DC. This voltage was applied for two minutes before the resistance was measured. Temperature Rise vs Specified Current Contact temperature was measured, while energized at the specified current of 8.74 amperes AC. Thermal imaging, (thermography) was used to determine the hot spots, and rated current. Vibration, Random Mated connectors were subjected to a random vibration test, specified by a random vibration spectrum, with excitation frequency bounds of 5 and 500 hertz. The power spectral density at 5 hz is 0.000312 G2/Hz. The spectrum slopes up at 6 dB per octave to a PSD of 0.02 G2/Hz at 14 Hz. The spectrum is flat at 0.02 G?/Hz from 14 to 500 Hz. The root-mean square amplitude of the excitation was 3.13 GRMS. The samples were subjected to this test for 20 minutes in each of three mutually perpendicular axes for a total of 1 hour. The connectors in Group - 1 were monitored for discontinuities greater than one microsecond using a current of 100 milliamperes in the monitoring circuit. During the vibration of Group - 2 the connectors were energized at 18 degrees C level for 100% loading.501-305 Rev. O Page 7 3.7 3.8 3.9 3.11 Physical Shock Mated connectors were subjected to a physical shock test, having a sawtooth waveform of 100 gravity units (g peak) and a duration of 6.0 milliseconds. Three shocks in each direction were applied along the three mutually perpendicular planes, for a total of 18 shocks. The connectors were monitored for discontinuities greater than one microsecond using a current of 100 milliamperes in the monitoring circuit. Mating Force The force required to mate individual connectors was measured using a tensile/compression device and a free floating fixture. The crosshead speed was 1.5 mm per second. Unmating Force The force required to unmate individual connectors was measured using a tensile/compression device and a free floating fixture. The crosshead speed was 1.5 mm per second. : Contact Retention A force of 22 newtons was applied to the header contacts for 10 seconds in each direction. Durability Headers were mated and unmated 5000 times at a rate not exceeding 600 per hour. The battery housings were mated and unmated 1000 times at a rate not exceeding 600 per hour. Solderability Connector assembly contact solder tails were subjected to a solderability test by immersing them in a mildly activated rosin flux for 5 to 10 seconds, allowed to drain for 10 to 6O seconds, then held over moiten solder without contact for 2 seconds. The solder tails were then immersed in the molten solder at a rate of approximately one inch per second, held for 3 to 5 seconds, then withdrawn. After cleaning in isopropyl alcohol, the samples were visually examined for solder coverage. The solder used for testing was 60/40 tin lead composition and was maintained at a temperature of 245C. Thermal Shock Unmated connectors were subjected to 25 cycles of temperature extremes with each cycle consisting of 30 minutes at each temperature. The temperature extremes were -30C and + 105C. The transition between temperatures was less than one minute.501-305 Rev. O Page 8 3.14 Humidity-Temperature Cycling Unmated connectors were exposed to 10 cycles of humidity-temperature cycling. Each cycle lasted 24 hours and consisted of cycling the temperature between 25C and 65C twice while the relative humidity was held at 95%. (During five of the first nine cycles, the connectors were exposed to a cold shock at -10C for 3 hours.} TEMPERATURE-HUMIDITY CYCLING (109-23-4) : : 80-96%: : 80-90% : : : 70 |e 90-96% RH 916-94 90-08% RH 919) 90-98% RH o : a E & g 5 6 -20 : : : : : . : : : : : o 2 4 6 8 10 12 14 16 18 20 22 24 Time (hours} Figure 3 3.15 Temperature Life Mated samples were exposed to a temperature of 105C for 480 hours.501-305 Rev. O Page 9 4. Validation Prepared by: Ailllanns a Ai bo WZigs William L. Scharff Engineering Assistant Product Qualification Team Corporate Test Laboratory Reviewed by: LT eo Robert S. Druckenmiller Supervisor Product Testing Corporate Test Laboratory Approved by: Gr CLK ZD. Bil eee Edward Gill Manager Engineering and Design Assurance Capital Goods Business Unit