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. 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