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family: model: halt halt temperature cycling step stress halt operating temperature range: pass halt vibration step stress maximum operating level: pass condor non-operating vibration result: pass cold start-up time result: pass ir imaging and thermal survey status: done please see attached report for detail implementation of a fix is technically or economically unfeasible. the greater the design margin, environmental report: executive summary 07/15/05 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. GPMP600-24 revision: a 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 gpmp / gphp acceptable level is usually a point where the fundamental design limit is reached, or 2311 statham parkway iso 9001-2000 certified oxnard, california 93033 telephone (805) 486-4565 fax (805) 487-8911 www.condorpower.com a subsidiary of sl industries, inc. 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. the less likely that a field failure will occur due to that particular stimulus. 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.
2311 statham parkway oxnard, california 93033 family: model: overview a total of 2 units were exposed to the following testing: model serial number test GPMP600-24 104-7389a-0003 ir, thermal survey, thermal halt cold, cold start, vibration halt GPMP600-24 035-14917-0002a thermal halt hot test results for gpmp temperature cycling step stress specification limits maximum specified operating temperature +50c minimum specified operating temperature -20c operational limits maximum operating temperature (no degradation of performance): +70c minimum operating temperature (no degradation of performance): -40c result table temp (c) incorp. root cause corrective action +80c no output. q7 and q8 burned up. none. unit reached fundamental limit of operation. telephone (805) 486-4565 fax (805) 487-8911 www.condorpower.com environmental / halt test report a subsidiary of sl industries, inc. iso 9001 certified 07/15/05 revision: gpmp / gphp GPMP600-24 a problem -
v ibration step stress specification limits minimum specified operating level (no loss of operation): 1.5 g rms operational limits maximum operating level (no loss of operation): 5 g rms result table test summary infrared baseline photo unit is allowed to stabilize at approximately 25c ambient temperature, convection cooled, with 600 w output power before infrared photo is shot. see attached topside and bottomside photo. thermal survey 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. v ibration qualification one hour of random vibration in each of three (3) orthogonal axes. profile: 0.038 g 2 /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.) c10, c40, c48 broke. l2 and part of t3 lead broken. trace bared beneath t3. - root cause no rtv on c13. no rtv on c40 or c48; a little rtv on c10. rtv only between board and t2 on one end. added rtv between board and t2 on both ends of t2. - - 7 g rms, y axis none. none. unit reached fundamental limit of technology. 7 g rms, y axis #4 lead of t2 broke. 7 g rms, x axis a dded generous amounts of rtv between c40, c48, c10 and their surrounding components. - 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. 5 g rms, y axis added rtv between c13 and surrounding components. incorp. level (g rms ) corrective action problem c13 broke.
23.6c 70.3c 25 30 35 40 45 50 55 60 65 70 sp01 sp02 sp03 sp04 sp05 sp06 sp07 sp08 sp09 sp10 ambient GPMP600-24 ir label value sp01 56.1c sp02 52.4c sp03 44.8c sp04 56.9c sp05 49.0c sp06 54.5c sp07 64.7c sp08 44.5c sp09 46.2c sp10 60.6c ambient 25.0c notes: 115 vac input output: 24 vdc @ 25 a 25c ambient unit cooled by internal fans.
c1 40 c 35 c 32 c 66 c 63 c 57 c c14 29 c 28 c 28 c 53 c 54 c 53 c c16 30 c 29 c 29 c 54 c 55 c 54 c c2 40 c 36 c 34 c 65 c 63 c 58 c c3 39 c 35 c 32 c 65 c 63 c 58 c c38 39 c 37 c 38 c 64 c 64 c 64 c pcb by cr22 63 c 61 c 62 c 89 c 90 c 89 c cr1 60 c 51 c 39 c 83 c 77 c 63 c cr22 69 c 68 c 68 c 93 c 93 c 92 c cr6 56 c 51 c 46 c 79 c 76 c 69 c l1 41 c 35 c 31 c 67 c 62 c 56 c l2 43 c 36 c 31 c 69 c 64 c 57 c l3 54 c 53 c 53 c 80 c 81 c 80 c q15 55 c 44 c 35 c 84 c 72 c 60 c q6 48 c 40 c 34 c 74 c 67 c 59 c q7 41 c 39 c 40 c 67 c 68 c 68 c q8 57 c 55 c 56 c 85 c 86 c 85 c r59 49 c 48 c 48 c 73 c 74 c 73 c pcb by rt1 80 c 71 c 54 c 101 c 93 c 75 c t1 55 c 43 c 34 c 80 c 71 c 59 c t2 46 c 38 c 32 c 71 c 65 c 57 c t3 37 c 33 c 31 c 62 c 60 c 56 c t6 coil 45 c 43 c 44 c 69 c 70 c 69 c t6 core 51 c 50 c 51 c 74 c 75 c 75 c t7 coil 32 c 31 c 32 c 56 c 57 c 57 c t7 core 30 c 29 c 30 c 54 c 55 c 55 c u1 36 c 34 c 35 c 60 c 61 c 60 c u2 43 c 41 c 41 c 67 c 67 c 65 c u3 33 c 31 c 31 c 57 c 57 c 56 c under by rt1 74 c 65 c 51 c 96 c 89 c 73 c under cr27 61 c 60 c 61 c 90 c 92 c 91 c under cr7 42 c 41 c 41 c 70 c 71 c 70 c under q1 59 c 59 c 62 c 81 c 83 c 83 c under by r31 78 c 77 c 78 c 95 c 96 c 96 c under u3 41 c 40 c 40 c 69 c 70 c 69 c ambient 25 c 24 c 24 c 49 c 50 c 50 c ac input 92 vac 118 vac 263 vac 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. component gpfm600-24 thermal survey 20 january 2005 25c low nom high 50c low nom high
90 vac 120 vac 260 vac 25c 3.575 s 2.645 s 1.265 s 0c -10c -20c -30c -40c 120 vac 2.665 s 2.665 s 2.695 s 2.695 s 2.765 s input ambient temperature cold start results time between application of ac power and measured output voltage: ambient input voltage
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. cum. level damage (qual=1) 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 pass/fail criteria: loss of output, or output is outside specified limit. random vibration step stress parameters monitored: vin, vout, signals as required (power good, etc.) time (min:sec) overall g rms psd gsqd/hz 10 hz 350 hz 2000 hz condor temperature halt profile -50 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 0 2 4 6 8 10 12 14 16 18 20 time (hrs.) temperature (c) tem p power 10 100 1000 2000 1 .1 .01 .001 .0001 frequency (hz) p o w e r s p e c t r a l d e n s i t y ( g / h z ) 2 condor halt random vibration profile y axis x axis z axis
thermal halt GPMP600-24 input and output 0 50 100 150 200 250 300 0 2 4 6 8 101214161820 time (hours) volts (ac) -60 -40 -20 0 20 40 60 80 100 120 degrees (celsius) ac input ambient -5 0 5 10 15 20 25 02468101214161820 time (hours) volts (dc) -5 0 5 10 15 20 25 30 current (amps) output current
GPMP600-24 thermal halt component temperature 1 -60 -40 -20 0 20 40 60 80 100 120 140 160 0 2 4 6 8 10 12 14 16 18 20 time (hours) degrees (celsius) c1 c14 c16 c2 c3 c38 cr1 cr22 cr6 l1 l2 l3 pcb by cr22 pcb by rt1 q15 q6 q7 q8 ambient
gmpm600-24 thermal halt component temperature 2 -60 -40 -20 0 20 40 60 80 100 120 140 160 0 2 4 6 8 10 12 14 16 18 20 time (hours) degrees (celsius) 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
typical thermal survey and halt setup. typical vibration qualification and halt setup. test setup
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