GPMP600 HALT Test Report

2311 STATHAM PARKWAY
OXNARD, CALIFORNIA 93033
TELEPHONE (805) 486-4565
a subsidiary of SL INDUSTRIES, INC.
FAX (805) 487-8911
ISO 9001-2000 CERTIFIED
www.condorpower.com
ENVIRONMENTAL REPORT: EXECUTIVE SUMMARY
07/15/05
FAMILY:
MODEL:
REVISION:
GPMP / GPHP
GPMP600-24
A
HALT
In order to increase the field reliability of its power supplies, Condor uses HALT (Highly Accelerated
Life Test) testing. This is a design margin test, where the test specimen is exposed to
successively higher levels of stress, until failure occurs. The failure mechanism is diagnosed,
corrected, and the process is repeated until an acceptable level of margin is achieved. An
acceptable level is usually a point where the fundamental design limit is reached, or
implementation of a fix is technically or economically unfeasible. The greater the design margin,
the less likely that a field failure will occur due to that particular stimulus.
HALT Temperature Cycling Step Stress
HALT Operating Temperature Range:
Pass
HALT Vibration Step Stress
Maximum Operating Level:
Pass
Condor Non-Operating Vibration
The product is exposed to random vibration, in order to simulate the environment encountered during
transportation. The product is exposed to 5 grms, 10-2000 hz random vibration, for 1 hour
per axis, in 3 axes. No mechanical or electrical damage is allowed.
Result:
Pass
Cold Start-up Time
The time measured, from the application of input voltage, for the unit to reach the specified output
voltage. This is measured at the specified temperature, as well as lower temperatures.
Result:
Pass
IR Imaging and Thermal Survey
The unit is photographed during operation with an imaging infrared camera to locate hot spots. The
major components, along with anything additionally identified during the IR scan, are
thermocoupled. Temperatures are measured at the maximum specified ambient temperature.
Status:
Done
Please see attached report for detail
2311 STATHAM PARKWAY
OXNARD, CALIFORNIA 93033
a subsidiary of SL INDUSTRIES, INC.
TELEPHONE (805) 486-4565
FAX (805) 487-8911
ISO 9001 CERTIFIED
www.condorpower.com
ENVIRONMENTAL / HALT
TEST REPORT
07/15/05
FAMILY:
MODEL:
REVISION:
GPMP / GPHP
GPMP600-24
A
Overview
A total of 2 units were exposed to the following testing:
Model
Serial Number
GPMP600-24
104-7389A-0003
GPMP600-24
035-14917-0002A
Test
IR, Thermal Survey, Thermal HALT Cold,
Cold Start, Vibration HALT
Thermal HALT Hot
Test Results for GPMP
Temperature Cycling Step Stress
Specification Limits
Maximum Specified Operating Temperature
Minimum Specified Operating Temperature
Operational Limits
Maximum Operating Temperature (No degradation of performance):
Minimum Operating Temperature (No degradation of performance):
Result Table
Problem
Temp (°C)
+80°C No output.
Root Cause
Q7 and Q8 burned up.
Corrective Action
None. Unit reached
fundamental limit of
operation.
+50°C
-20°C
+70°C
-40°C
Incorp.
-
Vibration Step Stress
Specification Limits
Minimum Specified Operating Level (No loss of operation):
Operational Limits
Maximum Operating Level (No loss of operation):
Result Table
Level (grms)
Problem
Root Cause
No RTV on C13.
5 grms, Y C13 broke.
axis
7 grms, X C10, C40, C48 broke. No RTV on C40 or
C48; a little RTV on
axis
C10.
7 grms, Y #4 lead of T2 broke.
axis
Corrective Action
1.5 grms
5 grms
Incorp.
Added RTV between C13 and
surrounding components.
Added generous amounts of RTV
between C40, C48, C10 and their
surrounding components.
RTV only between
Added RTV between board and
board and T2 on one T2 on both ends of T2.
end.
7 grms, Y L2 and part of T3 lead None.
broken. Trace bared
axis
beneath T3.
None. Unit reached fundamental
limit of technology.
-
-
-
-
Test Summary
Infrared Baseline Photo
Unit is allowed to stabilize at approximately 25°C ambient temperature, convection cooled, with
600 W output power before infrared photo is shot. See attached topside and bottomside photo.
Thermal Survey
After attaching thermocouples, unit is placed in the chamber, powered on, and allowed to reach a
stable temperature. Component temperature is monitored throughout the test. See attached chart for
all configurations.
Cold Start
Unit is placed in the chamber, power off, and allowed to stabilize at the ambient temperature.
With an oscilloscope probe attached to both the input and the output, power is applied and the
time difference between application of power and output voltage is recorded. See attached chart
for all configurations.
Vibration Qualification
One hour of random vibration in each of three (3) orthogonal axes. Profile: 0.038 g2/hz,
20-350 hz; -60 B/oct, 350-2000 hz; 4.86 grms.
HALT Temperature Cycling Step Stress and Vibration
Unit is exposed to progressively more severe operating temperatures and random vibration
environments. Failures that occur are diagnosed for root cause, corrective action is performed, and
then the test is continued. The levels are increased unti the test extremes or the fundamental limit
of the unit is reached (whether by technological or economic limitations.)
GPMP600-24 IR
70.3°C
70
65
SP05
SP04
SP03
SP06
60
SP02
55
SP07
50
SP10
SP08
SP09
SP01
45
40
35
30
AMBIENT
25
23.6°C
Label
Value
SP01
56.1°C
SP02
52.4°C
SP03
44.8°C
SP04
56.9°C
SP05
49.0°C
SP06
54.5°C
SP07
64.7°C
SP08
44.5°C
SP09
46.2°C
SP10
60.6°C
AMBIENT
25.0°C
NOTES:
115 VAC INPUT
OUTPUT: 24 VDC @ 25 A
25°C AMBIENT
Unit cooled by internal fans.
GPFM600-24 THERMAL SURVEY
20 JANUARY 2005
C1
C14
C16
C2
C3
C38
PCB BY CR22
CR1
CR22
CR6
L1
L2
L3
Q15
Q6
Q7
Q8
R59
PCB BY RT1
T1
T2
T3
T6 COIL
T6 CORE
T7 COIL
T7 CORE
U1
U2
U3
UNDER BY RT1
UNDER CR27
UNDER CR7
UNDER Q1
UNDER BY R31
UNDER U3
LOW
40 °C
29 °C
30 °C
40 °C
39 °C
39 °C
63 °C
60 °C
69 °C
56 °C
41 °C
43 °C
54 °C
55 °C
48 °C
41 °C
57 °C
49 °C
80 °C
55 °C
46 °C
37 °C
45 °C
51 °C
32 °C
30 °C
36 °C
43 °C
33 °C
74 °C
61 °C
42 °C
59 °C
78 °C
41 °C
25°C
NOM
35 °C
28 °C
29 °C
36 °C
35 °C
37 °C
61 °C
51 °C
68 °C
51 °C
35 °C
36 °C
53 °C
44 °C
40 °C
39 °C
55 °C
48 °C
71 °C
43 °C
38 °C
33 °C
43 °C
50 °C
31 °C
29 °C
34 °C
41 °C
31 °C
65 °C
60 °C
41 °C
59 °C
77 °C
40 °C
AMBIENT
25 °C
24 °C
AC INPUT
92 VAC 118 VAC 263 VAC
COMPONENT
HIGH
32 °C
28 °C
29 °C
34 °C
32 °C
38 °C
62 °C
39 °C
68 °C
46 °C
31 °C
31 °C
53 °C
35 °C
34 °C
40 °C
56 °C
48 °C
54 °C
34 °C
32 °C
31 °C
44 °C
51 °C
32 °C
30 °C
35 °C
41 °C
31 °C
51 °C
61 °C
41 °C
62 °C
78 °C
40 °C
24 °C
LOW
66 °C
53 °C
54 °C
65 °C
65 °C
64 °C
89 °C
83 °C
93 °C
79 °C
67 °C
69 °C
80 °C
84 °C
74 °C
67 °C
85 °C
73 °C
101 °C
80 °C
71 °C
62 °C
69 °C
74 °C
56 °C
54 °C
60 °C
67 °C
57 °C
96 °C
90 °C
70 °C
81 °C
95 °C
69 °C
50°C
NOM
63 °C
54 °C
55 °C
63 °C
63 °C
64 °C
90 °C
77 °C
93 °C
76 °C
62 °C
64 °C
81 °C
72 °C
67 °C
68 °C
86 °C
74 °C
93 °C
71 °C
65 °C
60 °C
70 °C
75 °C
57 °C
55 °C
61 °C
67 °C
57 °C
89 °C
92 °C
71 °C
83 °C
96 °C
70 °C
HIGH
57 °C
53 °C
54 °C
58 °C
58 °C
64 °C
89 °C
63 °C
92 °C
69 °C
56 °C
57 °C
80 °C
60 °C
59 °C
68 °C
85 °C
73 °C
75 °C
59 °C
57 °C
56 °C
69 °C
75 °C
57 °C
55 °C
60 °C
65 °C
56 °C
73 °C
91 °C
70 °C
83 °C
96 °C
69 °C
49 °C
50 °C
50 °C
91 VAC 116 VAC 264 VAC
OUTPUT
24 VDC 24 VDC 24 VDC
24 VDC 24 VDC 24 VDC
CURRENT
25 A
25 A
25 A
25 A
25 A
25 A
Note: Component names with "under" are on the underside of the board. The thermocouples
by RT1 and R31 are attached on the underside of the board to the board itself; the reference
designators are given to tell the general area where they are attached.
Cold Start Results
Time between application of AC power and measured output voltage:
Ambient
25°C
Input
120 VAC
90 VAC
3.575 s
0°C
2.665 s
Input Voltage
120 VAC 260 VAC
2.645 s
1.265 s
Ambient Temperature
-10°C
-20°C
-30°C
2.665 s
2.695 s
2.695 s
-40°C
2.765 s
Temperature (°C)
Condor Temperature HALT Profile
100
90
80
70
60
50
40
30
20
10
0
-10
-20
-30
-40
-50
Temp
Power
0
2
4
6
8
10
12
14
16
18
20
Time (Hrs.)
Power Cycling: Five OFF/ON cycles (1 Min ON / 1 Min OFF) are performed at the end of each dwell.
Parameters monitored: Vin, Vout, signals as required (power good, etc.)
Pass/Fail criteria: Loss of output, or output is outside specified limit.
Random Vibration Step Stress
PSD Gsqd/Hz
Cum.
Damage
(Qual=1)
Level
Time
(min:sec)
Overall
Grms
10 Hz
350 Hz
2000 Hz
1
10:00
5
0.038
0.038
0.0012
0.17
2
10:00
7
0.078
0.078
0.0024
1.6
3
10:00
9
0.129
0.129
0.004
9
4
10:00
11
0.192
0.192
0.0059
37
5
10:00
13
0.269
0.269
0.0082
120
Parameters Monitored: Vin, Vout, signals as required (power good, etc.)
Pass/Fail criteria: Loss of output, or output is outside specified limit.
Condor HALT Random Vibration Profile
2
Power Spectral Density (G /Hz)
1
.1
.01
.001
X Axis
Y Axis
.0001
10
100
Frequency (Hz)
1000
2000
Z Axis
VOLTS (AC)
VOLTS (DC)
120
THERMAL HALT
GPMP600-24 INPUT AND OUTPUT
300
100
80
20
250
18
60
16
-5
0
5
10
15
20
25
30
200
14
20
40
20
12
18
150
10
16
0
8
12
AMBIENT
TIME (HOURS)
AC INPUT
10
TIME (HOURS)
CURRENT
14
100
6
8
-20
-40
4
6
50
2
4
-60
0
2
0
25
20
15
10
5
0
-5
0
OUTPUT
DEGREES (CELSIUS)
CURRENT (AMPS)
DEGREES (CELSIUS)
160
140
120
100
80
60
40
20
0
-20
-40
-60
0
2
4
6
10
12
14
GPMP600-24 THERMAL HALT
COMPONENT TEMPERATURE 1
8
TIME (HOURS)
16
18
20
C1
C14
C16
C2
C3
C38
CR1
CR22
CR6
L1
L2
L3
PCB BY CR22
PCB BY RT1
Q15
Q6
Q7
Q8
AMBIENT
DEGREES (CELSIUS)
160
140
120
100
80
60
40
20
0
-20
-40
-60
0
2
4
6
10
12
14
GMPM600-24 THERMAL HALT
COMPONENT TEMPERATURE 2
8
TIME (HOURS)
16
18
20
R59
T1
T2
T3
T6 COIL
T6 CORE
T7 COIL
T7 CORE
U1
U2
U3
UNDER BY R31
UNDER BY RT1
UNDER CR27
UNDER CR7
UNDER Q1
UNDER U3
AMBIENT
Test Setup
Typical thermal survey and HALT setup.
Typical vibration qualification and HALT setup.
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